Buffalo Box #6: Gluing up and finishing

Well I managed to get all of the intarsia pieces cut, shaped and fitted into the lid of the box so now it’s time to glue everything in place. I like to remove a few pieces at a time and glue them in. In these photos I use a pin to pry a piece up so that I can apply CA glue.

I will continue removing pieces and applying glue until all pieces are glued into place.

Everything is glued in and looking good.

Once the glue is dry, it’s time to apply the finish to the intarsia. I like to use a spray-on satin poly for my finish. I begin by blowing off any dust that might be between the pieces. Because the box itself will be finished with a wipe on poly, I mask off the top edges of the lid with packing tape and spray the top from all directions to get in -between all pieces. Three coats will do it.

I’ve gone ahead and applied the three coats to the lid and wiped on three coats to the box. Now it’s time to install the hinges. I begin by taping the lid to the box, carefully lining up the corners. I position the hinges and tape them in place.

In the next photo, I’m using a 1/16” drill bit to drill pilot holes for the #2×3/8” screws.

To keep from twisting the heads off of the screws, I dip the screws in vegetable oil.
Hinges installed.

Well the box is done except for the inside lining.This photo shows the material that I will be using to line the top and bottom of the box. I use a rotary cutter and a square to cut the material.

Once the material has been cut, I like to treat the edges with Fray-check to prevent fraying.

I install the fabric using clear fabric glue around the edges and throughout the center.

Here I have attached the wood description list to the back of the box, signed and dated—-DONE

One pair of custom Buffalo boxes ready for delivery.

-- Mike --www.midlothianwoodworks.com