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Forum topic by Jim Crockett (USN Retired) posted 09-03-2009 04:47 AM 3215 views 0 times favorited 6 replies Add to Favorites Watch
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Jim Crockett (USN Retired)

852 posts in 3759 days

09-03-2009 04:47 AM

Anyone have an idea of how this box was constructed? My thought is a block of walnut was slided in half then a router and template were used to hollow out the interiors. I’m not sure, though, because of the interior corner angles; it would be hard to get that nice sharp 135-deg edge to corner angle. But maybe it was cleaned up with a chisel.

Never seen a box made just like this but have been cogitating on why a box couldn’t be made with a router – just hollowing out a length of stock, either with a template or on a router table with stops.

I emailed the guy asking some questions but never received an answer.

Sure is a nice looking box!


-- A veteran is someone who, at one point in his/her life, wrote a blank check made payable to "The United States of America," for an amount of "up to and including his/her life".

6 replies so far

View patron's profile


13607 posts in 3367 days

#1 posted 09-03-2009 05:09 AM

well jim ,

you asked ,
and this time you answered too !

a router with a template guide ,
and a inside cutout profile cut into a template .
or a pin router with the same template .
a plunge router and step down in passes .
a router table with stops is good to ,
with an upcut spiral bit ( upcut , so it pulls the chips ,
down , as the router is upside down )
a 1/2” bit would give you a 1/4 ” radius in the corner ,
not worth chiseling !

good luck ,
and lets see the finished box when you are done .

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View a1Jim's profile


117120 posts in 3603 days

#2 posted 09-03-2009 05:30 AM

I was guessing a bandsaw box but I like davids idea better.

-- wood crafting & woodworking classes

View John Ormsby's profile

John Ormsby

1288 posts in 3763 days

#3 posted 09-03-2009 07:07 AM

Patron is correct. They are very easy to make. Take small cuts so as not to get grain tear out.

-- Oldworld, Fair Oaks, Ca

View TopamaxSurvivor's profile


18290 posts in 3702 days

#4 posted 09-03-2009 07:31 AM

I’ll bet on the router ;-))

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View scrappy's profile


3507 posts in 3457 days

#5 posted 09-03-2009 08:46 AM

Patron has it. Only I think they re-sawed the board first. The grain in front matches pretty good so looks like top and bottom were one piece. Cut, routered then hinged.

Looks VERY simular to the “Pen Boxes” I have seen at Woodworkers Source.

-- Scrap Wood's the best...the projects are smaller, and so is the mess!

View DaneJ's profile


56 posts in 3235 days

#6 posted 09-03-2009 04:11 PM

Resaw or book match a piece from the same board.

I have prototyped a box very similar to the pen box, here are some notes on what I have done so far:

hinges are the 5mm barrel hinges, I think the 10mm are just too large, maybe ok for a “presentation” or boat bag, box but if I am going to carry it in my vest pocket it is just too bulky.
Duplicated the 45deg chamfer on both sides, for simplicity and a finger-grip to open, also if you book-match vs. resaw then the chamfer hides the fact that the top and bottom do not have perfectly matching grain.
Rare earth magnets for the ‘latch’
Interior is routed with a bowl and tray bit then ripplefoam is attached. Google found a bunch of sources for ripplefoam.

I don’t have any pictures, mainly because I am still prototyping some details, and there are a number of boo-boos and unappealing scrap poplar.

-- Dane, Fairview Pk, OH. The large print giveth and the small print taketh away... Tom Waits

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