Glynne
Established Member
I started thinking about this in November last year and posted a couple of questions: -
Square punch
Which wood filler
So many thanks to Custard and everyone else who took the time to advise.
I did start off with the intention of doing a full WIP but as time went on..........., but I'll post what I have and hope they will be of some interest.
The start, mahogany in my moxon vice
Once the fingers were cut, the edges were eased with a rounding over cutter on a router table.
However, you can't get into the corners and these have to be done by hand - which takes a while!
Then the peg holes were cut using a hollow mortise chisel. To keep the edges clean, square and in the right position I used a scruffy homemade jig.
. Once marked out, I could then deepen the square peg sockets with a chisel.
Once drilled, I then assembled each corner and carefully drilled pilot holes into the corresponding finger socket and fixed with temporary screws.
The box was checked for square
Then the first mistake became apparent - I shouldn't have rounded of the internal parts of the fingers....!
So a new design decision was taken to line the completed box.
Its a this point that the pictures dry up due to family, birthdays, Christmas and a ruby wedding anniversary holiday.
However I think it is the G & G joint that will be of most interest and this was just copied for the base which overlaps by about 10mm.
The top is simply 3 jointed strips of mahogany with bread board ends - the ends located and stabilised with biscuits and screwed in place.
To make the pegs, I used the jig described in the book "In the Greene & Greene Style" by Darrell Peart which MartinCox kindly lent me.
So then it was take everything apart, fill the mahogany with the filler recommended by Custard, allow to dry then finely sand and then stain.
Having spent so long so far, the idea of french polishing went and I used several coats of danish oil instead.
The box was then reassembled with a few dabs of glue as well as the screws - both the box and the inside of the plinth have bases (veneer on thin MDF) which is rebatted in and glued to add strength.
The box was then lined with pig suede (from my supplier recommended by Marcos).
I initially added a tray in merranti (box joint corners - cutter from Wealdens Tools) and made some tray lifts from brass bar (B&Q). However the tray was far too deep so I added a second "jewellery tray" out of rosewood (ex David Stanley Auction) which gives a secret
space underneath. Box trays were lined with the same pig suede.
I'll add pictures of the completed box below.
Square punch
Which wood filler
So many thanks to Custard and everyone else who took the time to advise.
I did start off with the intention of doing a full WIP but as time went on..........., but I'll post what I have and hope they will be of some interest.
The start, mahogany in my moxon vice
Once the fingers were cut, the edges were eased with a rounding over cutter on a router table.
However, you can't get into the corners and these have to be done by hand - which takes a while!
Then the peg holes were cut using a hollow mortise chisel. To keep the edges clean, square and in the right position I used a scruffy homemade jig.
Once drilled, I then assembled each corner and carefully drilled pilot holes into the corresponding finger socket and fixed with temporary screws.
The box was checked for square
Then the first mistake became apparent - I shouldn't have rounded of the internal parts of the fingers....!
Its a this point that the pictures dry up due to family, birthdays, Christmas and a ruby wedding anniversary holiday.
However I think it is the G & G joint that will be of most interest and this was just copied for the base which overlaps by about 10mm.
The top is simply 3 jointed strips of mahogany with bread board ends - the ends located and stabilised with biscuits and screwed in place.
To make the pegs, I used the jig described in the book "In the Greene & Greene Style" by Darrell Peart which MartinCox kindly lent me.
So then it was take everything apart, fill the mahogany with the filler recommended by Custard, allow to dry then finely sand and then stain.
Having spent so long so far, the idea of french polishing went and I used several coats of danish oil instead.
The box was then reassembled with a few dabs of glue as well as the screws - both the box and the inside of the plinth have bases (veneer on thin MDF) which is rebatted in and glued to add strength.
The box was then lined with pig suede (from my supplier recommended by Marcos).
I initially added a tray in merranti (box joint corners - cutter from Wealdens Tools) and made some tray lifts from brass bar (B&Q). However the tray was far too deep so I added a second "jewellery tray" out of rosewood (ex David Stanley Auction) which gives a secret
space underneath. Box trays were lined with the same pig suede.I'll add pictures of the completed box below.
