Buffalo Box #2: Box Glue-up

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Blog entry by wdkits1 posted 11-11-2009 05:41 PM 2485 reads 3 times favorited 16 comments Add to Favorites Watch
« Part 1: Milling the stock Part 2 of Buffalo Box series Part 3: The Pattern »

In my first installment I showed the steps to cut and prep the stock for the custom keepsake box.
This installment shows the steps to glue -up the box and cut the lid.
I begin by gluing in the accent strips on all of the box sides. I am using Holly strips that I sized 1/4” wide by 1/8” thick

I use CA glue and tap them in place.

Once the glue has set up I use a small flex-blade saw to trim the ends flush with the miters.

I use a sanding block to sand the strips flush with the box side.

Now is also the time to sand all of the insides of the box sides up to 220 grit.

In this next photo, I’m using my rotary tool with a 5/64” high speed bit to make small holes in the miters to give the glue joint extra strength being careful not to drill through the side and not drilling 3/4” down from the top of the box where the lid will be separated.

I’ve cut the backer boards to fit in the grooves and do a dry fit to make sure all of the miters fit tight and the box is square.

Now comes the fun part. Laying all of the box sides in the right sequence against a straight edge I tape the ends together using packing tape stretched tight to pull the miters together.

Carefully flipping the box sides over I apply glue to the backer grooves and to the miters.

Setting the top and bottom backers in place I now pull the sides together and tape the last corner together with packing tape.

Squaring the glued box with a framing square I pull the corners tight with packing tape stretched diagonally on the top and bottom of the box.

After the glue has dried and the tape has been removed I sand the sides of the box to 220 grit.

In the next photos, I have set the fence of the bandsaw 3/4” from the blade and have placed the top of the box against the fence. Saw through until the lid is separated.

Lid separated from box

Over to the router to round off the top and bottom edges of the box using a 1/4” roundover bit.

Remove saw marks on the inside edges of the box and lid by sanding with 100grit sandpaper on a flat surface.

Box is ready for finishing and hinges—but not yet.

My next entry will be designing the pattern and starting the intarsia.

-- Mike --

16 comments so far

View bigike's profile


4052 posts in 3289 days

#1 posted 11-11-2009 06:52 PM

nice inlay what kind of wood is the box and inlay the inlay looks like holly and the box walnut?

-- Ike, Big Daddies Woodshop,

View Partridge's profile


296 posts in 3956 days

#2 posted 11-11-2009 07:37 PM

i am confused about the dimpling of the end grain????

-- I get out in the shop when I can

View grizzman's profile


7836 posts in 3303 days

#3 posted 11-11-2009 07:44 PM

i love this series…always enjoy watching another jock create there projects…always things to learn…thankyou…look forward to the next step….

-- GRIZZMAN ...[''''']

View patron's profile


13604 posts in 3341 days

#4 posted 11-11-2009 08:01 PM

good blog ,

i do the same thing ,
except i do all the exterior work and the finishing ,
before i cut the box open .
that way if the finish is screwed up i can sand it off and try again .
i just put tape to the relevant parts where they will get scratched
as they go thru the bandsaw .

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

View Bob N's profile

Bob N

131 posts in 3927 days

#5 posted 11-11-2009 08:01 PM

This is an awesome tutorial, thanks for taking the time to do this!

View a1Jim's profile


117095 posts in 3577 days

#6 posted 11-11-2009 08:07 PM

Super Blog Mike

-- wood crafting & woodworking classes

View wdkits1's profile


215 posts in 3353 days

#7 posted 11-11-2009 08:18 PM

Thanks for the nice comments guys. To Ike—you are correct-holly inlays, walnut box
To partridge—end grain glue-ups are typically weak so by adding the little holes in the miters it gives the glue more area to hold on to.

-- Mike --

View huff's profile


2828 posts in 3285 days

#8 posted 11-11-2009 08:50 PM

Very informative blog Mike. Your blog is very easy to follow along. Good job. Looking forward to next one.

-- John @

View Raspar's profile


246 posts in 3148 days

#9 posted 11-11-2009 09:33 PM

can not wait for the intarsia piece. I have done a couple but love seeing other.

-- Have thy tools ready. God will find thee work.

View Dan'um Style's profile

Dan'um Style

14172 posts in 3983 days

#10 posted 11-12-2009 02:19 AM


-- keeping myself entertained ... Humor and fun lubricate the brain

View mtkate's profile


2049 posts in 3325 days

#11 posted 11-12-2009 02:48 AM

wow and wow. thanks for this blog. Seeing how you cut the lid was amazing. I am still struggling getting straight lines from my bandsaw (even with checking adjustments, the miter, etc etc). Obviously a skills thing.

View cabinetmaster's profile


10874 posts in 3558 days

#12 posted 11-12-2009 03:09 AM

Great blog Mike. It is very easy to follow and I can’t wait to see the intarsia that goes on the lid. Thanks for this great tutorial.

-- Jerry--A man can never have enough tools or clamps

View KevinVan's profile


91 posts in 3151 days

#13 posted 11-12-2009 04:38 AM

I’m inspired by this…Can’t wait to see it finished!

-- ALS IK KAN “to the best of my ability,”

View griff's profile


1207 posts in 3762 days

#14 posted 11-12-2009 06:01 AM

Enjoyed this, good tutorial.

-- Mike, Bruce Mississippi = Jack of many trades master of none

View stefang's profile


15881 posts in 3334 days

#15 posted 11-12-2009 10:12 PM

Really great tutorial Mike. I thought your idea to dimple the miters was a very good one. I am just now doing some similar work and I will surely use that technique. Thanks for sharing your methods. Looking forward to the next in the series.

-- Mike, an American living in Norway.

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