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Forum topic by mwrhb posted 03-17-2014 03:20 AM 697 views 0 times favorited 3 replies Add to Favorites Watch
View mwrhb's profile


1 post in 1378 days

03-17-2014 03:20 AM

Topic tags/keywords: help staves box lid panel lunch box math questions ash bloodwood question joining shaping traditional


I am in the process of making my friend a lunch box out of some White Ash. It is a replica of the iconic construction worker’s metal curved top lunchbox. (Much like this on: Not too complicated in design.

However, I am having trouble with the side panel where the staves connect. those sides are going to have to be cut to be a (?) sided figure. I want the staves to be square, because in those gaps, I am going to fill it with Bloodwood.

How do I figure out how many sides these panel will need?

3 replies so far

View runswithscissors's profile


2127 posts in 1449 days

#1 posted 03-17-2014 05:08 AM

Being somewhat math challenged, I usually draw something like that full size, starting with a rough sketch, then refining it when it starts to look right.

That’s the way I built my C-top roll top desk, as trying to calculate widths of stiles and how much oversized to make the panels made my head hurt when I tried it any other way.

-- I admit to being an adrenaline junky; fortunately, I'm very easily frightened

View bondogaposis's profile


3972 posts in 1775 days

#2 posted 03-17-2014 05:24 AM

It depends on the width of the staves and the radius of the curve. A full size drawing will be the only way to get at the answer.

-- Bondo Gaposis

View MalcolmLaurel's profile


269 posts in 1047 days

#3 posted 03-17-2014 11:00 AM

An accurate drawing is the easiest way. When I did the treasure chest jewel box for my daughter, I laid it out on CAD because that’s easiest for me, then I printed the side plate full size, taped it to the end plate, and cut on the lines.

As a rough approximation if your top is wrapping around a full 180° (mine didn’t), pi times the radius divided by the width of the staves will give you the number of faces. Of course this won’t come out to be an even number unless you choose the radius and/or the stave width appropriately. In my case, I beveled the edges of the staves to the appropriate angle rather than leaving them square and adding a filler piece.

-- Malcolm Laurel -

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