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Custom Keepsake Box #3: Finished

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Blog entry by wdkits1 posted 08-26-2010 05:46 PM 1095 reads 0 times favorited 6 comments Add to Favorites Watch
« Part 2: The Dry Fit Part 3 of Custom Keepsake Box series no next part

One of the biggest challenges in the construction of this box was figuring out how to make the intersecting sections of the double miters strong enough . Normal end grain miter joints are pretty weak without using some sort of dowel of biscuit to reinforce them and in this case a double miter was even more challenging to strengthen. After playing with different options I decided to go with drilling multiple holes in the ends of the miters which will greatly add to the glue surfaces. I also decided to use a 2-part epoxy for the glue-up instead of wood glue.
I used a 5/64” high speed cutter in the dremel tool to make the holes in the end-grain miters.

I went ahead and did the final sanding and applied 2 coats of satin poly to all of the components before the glue-up to make it easier to clean up any glue squeeze out.

The glue up went real good and I had very little sanding to do .

I decided to use 2” brass hinges to attach the lid which I had to mortise in so I set up the router table with a 1/2” straight bit and using stop blocks and running a couple of test pieces dialed in the correct distances for the mortises.

Set up for hinge mortises

Once one side of the mortises are done then I shifted the stop blocks over to the second set of reference marks to complete to other mortises.
Clean up the round corners with a chisel and am good to go

So here are the photos of the box after the hardware is installed. Still have to apply another coat of finish and install to bottom liner. The completed box weighs in at 9 1/2lbs.

!!
This was a challenging project and I learned a few things that will come in handy someday .

-- Mike --http://www.custommade.com/by/mikemathieu/



6 comments so far

View ND2ELK's profile

ND2ELK

13495 posts in 2528 days


#1 posted 08-26-2010 08:50 PM

Simply beautiful. You did an excellent job on this box. Great craftsmanship as always. Very informative blogs. Thanks for posting.

God Bless
tom

-- Mc Bridge Cabinets, Iowa

View degoose's profile

degoose

7052 posts in 2109 days


#2 posted 08-26-2010 08:56 PM

Very Japanese in the joinery…

-- Drink twice... and don't bother to cut... @ lazylarrywoodworks.com.au For lovers of all things timber...

View shopmania's profile

shopmania

695 posts in 1936 days


#3 posted 08-26-2010 08:58 PM

very nice box. I have not yet attempted double miters. Good job!

-- Tim, Myrtle Beach, DrTim@ONeillChiro.com- Just one more tool, that's all I need! :)

View Broglea's profile

Broglea

669 posts in 1845 days


#4 posted 08-27-2010 02:17 AM

Wow. That is one beautiful box.

View wallkicker's profile

wallkicker

107 posts in 1908 days


#5 posted 08-28-2010 12:05 AM

Your projects always come out nice . Thanks for sharing it.

View Delta356's profile

Delta356

463 posts in 1608 days


#6 posted 10-12-2010 11:28 PM

That looks amazing,Great Job.
Thanks for showing.

Thanks, Michael Frey

FREY WOODWORKING INC.

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