Buffalo Box #6: Gluing up and finishing

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Blog entry by wdkits1 posted 12-31-2009 01:04 AM 1401 reads 4 times favorited 7 comments Add to Favorites Watch
« Part 5: More Intarsia tips and tricks Part 6 of Buffalo Box series no next part

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 --

7 comments so far

View John Gray's profile

John Gray

2370 posts in 3880 days

#1 posted 12-31-2009 01:12 AM

Thanks for keeping us updated on your beautiful box.

-- Only the Shadow knows....................

View KevinVan's profile


91 posts in 3146 days

#2 posted 12-31-2009 01:14 AM

This is the most impressive box I’ve ever seen.
If I try one someday can I copy your design?

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

View Occie gilliam's profile

Occie gilliam

505 posts in 3291 days

#3 posted 12-31-2009 03:15 AM

This was a very good Blog i learned a lot
Thanks for posting Mike
You do great worl

-- OC down in Costa Rica. come down and see me some time. I'll keep the light on for you

View webwood's profile


626 posts in 3245 days

#4 posted 12-31-2009 03:47 AM

thanks for the tips – love the box

-- -erik & christy-

View majeagle1's profile


1426 posts in 3491 days

#5 posted 12-31-2009 08:29 AM

Mike, thanks so much for the wonderful intarsia series blog. It was a great learning experience and I someday hope to be able to attempt it.
You do magnificent work !!!!! Thanks for sharing and taking the time to do the blog.

-- Gene, Majestic Eagle Woodworks,,

View a1Jim's profile


117090 posts in 3572 days

#6 posted 12-31-2009 08:32 AM

Fantastic boxes amazing work looks wonderful

-- wood crafting & woodworking classes

View fineamerican's profile


150 posts in 3110 days

#7 posted 01-07-2010 10:31 PM

That is remarkable job at detailing the many steps, thanks for your time, and sharing your skills!

-- John A. Thomas, South Carolina,

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