|Project by GeneR||posted 11-23-2013 08:40 PM||1776 views||2 times favorited||14 comments|
Hey guys sorry i haven’t put up a big project since the gun case but here it is my second keepsake / jewelry box which I have lovingly nicknamed the OH @#%&!!!!!!!! Box. :-)
This like a lot of my projects are experimental in how far i can push my self which usually ends up in failure and a lot and I mean a whole lot of cursing at my screw up. But I usually find away to fix or change the project on the fly hence the term “design on the fly”
This box is made from fiugured cherry that i had lying in my shop and an aromatic cedar top with a dyed copper top inlay. It started as a simple cherry box with 45 degreed corners and then i had the idea to make the splines look like they were stitched. So I marked everything out drilled 1/4” holes where the splines were going then used a plug cutter and made cedar plugs to match the lid (notice no cedar plugs in the box grrrrrr!) after gluing up and flush cutting the plugs i cut the splines which for some reason didn’t line up once they were cut, more cursing here loudly (the splines were to stop halfway through the plug) so back to the drill press which I do not have a table with a fence but will be rectifying in the near future. Looking around the next logical step was 3/8” walnut dowls, so i align everything and drill holes, upon inspection more cursing ensued as some of the dowels were not centered. Looking around the shop I found a 3/4” oak dowel and realized the problem was i did not have a good fence and some of the splines were cut wrong due to moving in the jig (1 more project to the shop upgrade list). At this point I had already glued the splines in. Then got the not so brilliant idea to put walnut dowels to contrast the oak giving a bullseye effect, I drilled and drilled and drilled some more. On ispection the cursing ensued once again. But they were left and no changing them at this point, andd maybe i was being to much of a perfectionist.
As the box dried i cut the cedar for the lid and test fitted the copper top and realized the 45s on the lid were not 45 degrees so let more cursing and a lot of sanding commence. I used a round over bit on the inside edges of the lid to give more of a finished picture frame look and i did plan on this lid overhanging the box. I noticed a smudge on the what I had believed to be an oxidized copper top so naturally i grab the alcohol and proceeed to wipe the entire hand stained finish off the copper. (cursing here loud enough for my neighbors to as well as a few things being thrown):-( , several days of trial and error and i refinished the copper as it is. And i glued the top up after prefinishing and waxing the pieces. Once glued i drilled dowel holes to lock in the corners of the lid an glued them in and flush cut. Then chamfered the top later on and had to refinish it again and there was more cursing.
As the @#%& lid was drying i went to hand plane the box to remove the biggest parts of glue as well as flatten all the splines before final sanding and finishing. This is where i realized poplar splines were probably not the best choice, as upon inspection again i noticed some of te corners chipped out of the splines while planing and then there was more cursing. After i went in and had several crown and cokes ,to soften the blows to my ego, i came up with the idea to chamfer the whole box an te lid to match, which I think came out rather nice. I sanded and finished the box with watco cherry danish oil and about 4 coats of semigloss laquer.
As i was getting ready to put the hinges on i realized the insie of the box top looked terrible with plain ply which was what backed the copper, just a little cursing here. So this is were I quickly educated my self on veneering and off to woodcraft to get cedar veneer for the top. The inside bottom is just sticky backed felt lining. For a first time veneering job i am alright with the way it turned out minus the cursing that went with the whole softening process, which will be for another story.
Finally the hinges went on and the box was waxed and polished with howards orange oil. So here it is and i hope you enjoyed my miserable journey once again. I also hope my neighbor appreciates all the work and headache that went into this box.
For an obsession that is so stressful I don’t know why I so enjoy it.
Let me know what you box experts think I am always open to criticism and new ideas.
-- Failure is always an option. :-)