|Project by Beorn||posted 10-28-2013 04:09 AM||1256 views||0 times favorited||6 comments|
I created this box at the request of a coworker. I was given specifications for size and a “natural” design, the rest was up to me. This box will serve as an urn so I kept the design simple and chose cedar for the warm tones. I also chose simple rabbited joinery.
The top and bottom are book matched and jointed and the sides are jointed from separate boards. I chose not to match the sides because I only had 1” lumber and I did not want to go thinner than 5/8” after finishing. The top and bottom pieces are both about 5/16”.
I wanted to do this project sans power tools but I had a devil of a time avoiding tear-out so I used a thickness planer to dimension the material and hand tools for every other step. I ripped the boards close to final dimension with a hand saw and planed to final width with a hand plane. I cross cut by hand and snuck up on final length with a shooting board. The grooves for the bottom were made with a chisel and a router plane. The hinge mortises were made the same way. The screws supplied with the hinges were too long so I filed them down with a medium mill file. I drilled the hinge screw holes with an egg beater drill and then used a full length screw to start the hole before switching to the filed screws. I chiseled a small chamfer on the front for a finger lift. I also chamfered the edges around the top and lid to help blend in the seam created by the top and lid. I used a card scraper to remove the planer marks and then sanded to 220 grit for a uniform appearance. I finished with bulls eye amber shellac applied with a foam brush and sanded with 220 grit. The second coat of shellac was followed by a rub down with 0000 steel wool and then a coat of minwax finishing wax buffed to a satin sheen.
If anyone spots a flaw in my finished product or technique please let me know. I’m fishing for criticism in order to become a better craftsman.
-- Try to learn something about everything and everything about something - Thomas Huxley