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Box Guy and Greer Keep Trying

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Project by Boxguy posted 701 days ago 3303 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  Box Sculptor's profile

Greg..the Cajun Box Sculptor

5020 posts in 1943 days


#1 posted 701 days ago

That is an absolutely awesome box.

-- If retiring is having the time to be able to do what you enjoy then I have always been retired.

View Monte Pittman's profile

Monte Pittman

13833 posts in 973 days


#2 posted 701 days ago

Very very nice

-- Mother Nature created it, I just assemble it. - It's not ability that we often lack, but the patience to use our ability

View DocSavage45's profile

DocSavage45

4915 posts in 1477 days


#3 posted 701 days ago

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

-- Cau Haus Designs, Thomas J. Tieffenbacher

View SebLolo's profile

SebLolo

65 posts in 851 days


#4 posted 700 days ago

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

1141 posts in 1259 days


#5 posted 700 days ago

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

2234 posts in 1650 days


#6 posted 700 days ago

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

14410 posts in 1439 days


#7 posted 700 days ago

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

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

View Boxguy's profile

Boxguy

1447 posts in 902 days


#8 posted 700 days ago

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 876 days


#9 posted 700 days ago

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

463 posts in 810 days


#10 posted 700 days ago

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

1494 posts in 907 days


#11 posted 700 days ago

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

1447 posts in 1149 days


#12 posted 700 days ago

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

951 posts in 2442 days


#13 posted 700 days ago

Has ‘cool factor.’

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

View whitebeast88's profile

whitebeast88

3481 posts in 825 days


#14 posted 700 days ago

beautiful.

-- Marty.Athens,AL

View dclark1943's profile

dclark1943

156 posts in 822 days


#15 posted 700 days ago

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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