|Project by Boxguy||posted 12-15-2012 05:40 AM||2420 views||3 times favorited||15 comments|
Pictured: This is Derrick’s gun box (16 x 11 x 5) featuring a top made from a Movingui tree that grew in Ghana, Africa, and sides made from a Black Cherry tree that grew in Southern Indiana. The paired corner splines are made of Black Walnut. Finished with wipe-on poly using this method. Derrick at work. (Below) He used my shop, but made this entirely on his own.
Focus: How do you cut out a shape for inside a box? To show the velvet covered cut out I had to run the contrast up and it distorted the color, but you get the idea. Derrick learned that he could cut out the outline of the gun in 1/2 inch thick foam using a utility knife. The outline was oversized by 1/8 inch or so to leave room for the cloth liner. He then attached the 1/2 inch foam to a 1 inch thick piece. He learned that a carbide burr spun by a battery powered drill gave him the control and speed he needed to “carve” Styrofoam. He dug out the space needed to accommodate the cylinder and barrel with the carbide burr. The whole Styrofoam piece was sized to leave a 1/4 inch gap on two sides and then the cloth was formed and glued on the Styrofoam and around the edges starting with the deepest area and working out to the edge again. I used a silmilar technique on this cutting board project. You could use this technique to make a formed space inside a box for tools, jewelry, or your rock collection.
Thanks: As always Derrick and I thank you for looking and a special thanks to all of you who take the extra time to leave questions or comments. I will respond to all of your posted comments in batches below this entry, so check back to see my responses.
P. S. Derrick also wants to extend his thanks for your comments and participation.
-- Big Al in IN