Construction Process

1.       Forming the block

Selected, cut, and glued wood

Used Reclaimed Native Dark Walnut

 Covered working surface with paper

 Glued 3 lengths together, spread even layer of wood glue

Clamped with Rockler wood clamps every 4 inches

 Squared off with clamp

Let dry 1 hour

Removed clamps

Recut edges to be square

2.       Cut the box

Marked wood block with pencil to indicate cut lines

Took block to bandsaw

Cut overall box shape/sides

Cut the lid from the base (1/2” blade)

Made dado cut with bandsaw into lid

Cut beveled compound angles around the lid

3.       Glued cut sides back on

Took the removed material, cut 1” long segment

Glued segment to one end of the lid to cap the end

Glued a second segment to the base to form male hinge side

4.       Drilled

Mounted base in a machining vise

Placed vise onto drill press

Drilled counter sink and counter bored holes (4.5” depth)

Used 1/8”, 1/4”, and 1/2” drill bits

Forstner drill bits were used to avoid chip out

Drilled hinge hole (1/4”) and magnet holes

Switched base for lid

Drilled hole (15/64”) for dowel hinge

                                Used Kreg pocket hole jig plan to create angle exterior holes in base

5.       Mounting

Lined up dowel hole on base and lid

Clamped in place

Spread glue in lid holes

Peened dowel rod in place

Let dry for 1 hour and then removed clamp

6. Sand and smooth

Used electric orbital sander for 60 – 100 grit

Hand sanded with 150, 180, 220, and 300 grit.

Buffed with Emery cloth

        7. Finishing

Oiled with Danish oil

Applied Wipe-on Poly/Miniwax

Used in a well-ventilated paintbooth

Buffed after each coat, applied 3 coats