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Box Guy and Greer Keep Trying

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Project by Boxguy posted 09-29-2012 04:51 AM 3691 views 42 times favorited 44 comments Add to Favorites Watch

Pictured: a jewelry box made from one solid piece of redwood burl. It is 12 1/2 inches tall, and an equilateral triangle with 8 1/2 inches on each of three sides. The finish is 4 coats of wipe-on poly applied with a one inch foam brush and carefully sanded with 800 grit paper after each coat. Then finished with Johnson’s Paste Wax applied with steel wool. The bark inclusions were filled with black epoxy and ground up alabaster then sanded.

Story: This box is a true collaboration. Most of the ideas were Greer’s a few were mine. We talked through the problems and concepts and methods of working as we went. Greer did almost all of the actual cutting in my shop and all of the sanding and finishing at his home. Making boxes with friends can teach you more than just woodworking. Working with Greer taught me that having buddies build boxes in my shop adds to the fun and is a great way to share learning.

Greer came across this wonderful burl in the course of his job as a veneer expert. It is a “core” left over after the veneer has been turned off the outside. There was a large bark inclusion in one side, and a crack or check in another area. Those flaws led us to the triangular shape as a way of salvaging the sound wood in the piece.

That shape in turn led us to the idea of spinning the sliced-up piece to get to the jewelry storage area. On a romantic note, Greer gave this jewelry box to the love of his life with an engagement ring inside. She accepted, and they are now a very happily married couple.

Construction Notes: You need a very definate sequence of steps in making this. It works a lot like making a band saw box.

1. Cut the three sides using a plywood pattern screwed onto each of the two ends. The plywood slides along on an extended bandsaw table clamped to the regular table.
2. Drill the long rod hole NOW almost the entire length of the piece so when you re-assemble the wood everything will line up perfectly. Stop a little short of drilling through the top of the box.
3. Slice off the top and bottom.
4. Slice off the back.
5. With the triangular “drawer” section still in one piece, round off the pivoting corner of the triangle.
6. Slice your “drawer” sections into drawers.
7. Use a Fostner bit to drill out the drawer storage section.
8. Insert a tight-fitting metal rod threaded at each end and draw up the drawers tightly with nuts before sanding anything.
9. We used a wide nylon washer between each drawer and tightened the nuts on each end of the rod pretty tightly, and it works very, very smoothly as the drawers glide and turn in and out.
10. Trim one of the end drawers a bit thinner to let the spacer-washers and fit-ups work out with the length of the back board.
11. We used screws in the bottom so we could take it apart and fit it together as we worked out the spacers and the top and bottom.

Thanks: to everyone who takes time to look at this. A special thanks to all who take time to make comments or offer advice. As always keep boxing and keep posting.

P. S. Greer asked me to thank all of you for your support and comments.

-- Big Al in IN





44 comments so far

View Greg..the Cajun Wood Artist's profile

Greg..the Cajun Wood Artist

5283 posts in 2063 days


#1 posted 09-29-2012 05:26 AM

That is an absolutely awesome box.

-- Each step of every Wood Art project I design and build is considered my masterpieceā€¦ because I want the finished product to reflect the quality and creativeness of my work

View Monte Pittman's profile (online now)

Monte Pittman

15533 posts in 1093 days


#2 posted 09-29-2012 05:26 AM

Very very nice

-- Mother Nature created it, I just assemble it.

View DocSavage45's profile (online now)

DocSavage45

5390 posts in 1597 days


#3 posted 09-29-2012 05:43 AM

Art in a box! A wow piece. Nice job guys!

-- Cau Haus Designs, Thomas J. Tieffenbacher

View SebLolo's profile

SebLolo

65 posts in 971 days


#4 posted 09-29-2012 06:31 AM

Very very nice Job ! And amazing result ! Congratulations.
I think, I’ll do one for my lovely wife when I’ll have time. Thx for her boxguy.

Seb

View murch's profile

murch

1186 posts in 1379 days


#5 posted 09-29-2012 07:37 AM

Looks wonderful. I love the bird in pic 2.

-- A family man has photos in his wallet where his money used to be.

View michelletwo's profile

michelletwo

2292 posts in 1770 days


#6 posted 09-29-2012 09:57 AM

Stellar!

-- We call the destruction of replaceable human made items vandalism, while the destruction of irreplaceable natural resources is called development.

View Roger's profile

Roger

15371 posts in 1558 days


#7 posted 09-29-2012 10:23 AM

Outstanding!! and Wow, of coarse. Way kool. Gr8 collaboration

-- Roger from KY. Work/Play/Travel Safe. Kentuk55@bellsouth.net

View Boxguy's profile

Boxguy

1543 posts in 1022 days


#8 posted 09-29-2012 10:32 AM

Responses to night owls and international viewers.

Greg, Hope your sales are going well. Your work keeps evolving in small, but significant ways.

Monte and Doc, thanks…always nice to hear from you guys.

Sheb, glad to hear from the French contingent. The key chains were fun to see. If I can help…ask. Keep to the sequence.

Murch, I liked your ash bowls dried in the microwave…nice forms. We can’t claim credit for the wonderful things we find hidden in the souls of trees…but the bird form was a real surprise.

Michelle, your router/lathe creations are really fun forms to see…what wild colors!

Roger, good morning. Looks like you have gone pen turning wild.

-- Big Al in IN

View TimWood's profile

TimWood

178 posts in 996 days


#9 posted 09-29-2012 11:01 AM

Al….you know that crowd you’re running with have gotten you doing some strange things. I don’t want to see my little Al get all MESSED UP with these people working on these equilateral new art deco projects!!! Come home little Al….we love you….show us a box….you know you wanna make one ….ANDY….KENT….JOEY….please try to reason with our friend….it’s those kids he’s hanging with…..... :)

-- Tim Harrelson

View Tom Godfrey's profile

Tom Godfrey

466 posts in 930 days


#10 posted 09-29-2012 11:32 AM

By far this is one of the finest Pieces that I can recall seeing on LJ. Every day brings better and more beautiful work of art from members of this site. You have done your share of art work in your boxes. Keep up the great work and I want to thank you for the advice you have given me and posting of how to make the straps to keep our boxes square.

-- Tom Godfrey Landrum South Carolina (tom@thcww.com)

View GrandpaLen's profile

GrandpaLen

1586 posts in 1027 days


#11 posted 09-29-2012 11:43 AM

Big Al,

‘Thinking Outside the Box’, and beautifully done.

The Bark Inclusion, IMHO, is a natural jewel in this piece.

Very nicely done. – Len

-- Mother Nature should be proud of what you've done with her tree. - Len ...just north of a stone's throw from the oHIo, river that is, in So. Indiana.

View Tennessee's profile

Tennessee

1584 posts in 1269 days


#12 posted 09-29-2012 01:02 PM

This is a true piece of art where the builders let the wood drive the project. Taking the triangle section as the best salvagable piece was great, and it made for a wonderful design that I’m sure will become an heirloom for someone!

-- Paul, Tennessee, http://www.tsunamiguitars.com

View Charles Maxwell's profile

Charles Maxwell

986 posts in 2562 days


#13 posted 09-29-2012 01:06 PM

Has ‘cool factor.’

-- Max the "night janitor" at www.hardwoodclocks.com

View whitebeast88's profile

whitebeast88

3610 posts in 945 days


#14 posted 09-29-2012 01:15 PM

beautiful.

-- Marty.Athens,AL

View dclark1943's profile

dclark1943

175 posts in 942 days


#15 posted 09-29-2012 01:21 PM

you do wonderful work, and a good job of explaining your process’s as well. Keep up the great work!

-- Dave, Kansas City

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