Prototype box to help a friend - Router Forums
 
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post #1 of 9 (permalink) Old 05-01-2010, 10:49 AM Thread Starter
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Default Prototype box to help a friend

At the Kansas City Woodworker's Guild we have an equipped shop that is open for the members to use. The requirements are that they sign a waiver, take and orientation and pass a written test (all the answers are variations on "don't do anything stupid") based on the orientation. Then they may use the shop so long as a "shop foreman" is on the premises. I'm one of about 12 shop foremen who come in on a regular basis for open shop time.

So, one of the new members asked me to help him with a 5th anniversary gift. We talked it over and decided on "box" since it would be small, practical and he only had about two weekends of free time. Yesterday we went and selected . Last week we agreed on a general pattern for the box. There was an article some years back in Fine Woodworking by Gary Rogowski where he built what looks like a sushi box. Nice lines, simple, minimum of tools. Perfect starter project.

So just to make sure I wouldn't cause my friend Jason any more problems than necessary, I did a prototype in some very sappy (and twisted) cherry.

Sides are on the order of 1/2" thick (really doesn't matter so long as they are thick enough but neither too thick or too thin). The overall size is about 10" x 4" x 2" but in my case it ended up a little under as I had to cut around some defects in the wood. The little handle piece is curly maple. Shellac and wax finish. Corner joinery is hand-cut but I did use a router for the bottom rabbet. The curve shape of the box was roughed in with handplanes, then faired with a cardscraper and finally hit with 220 to even out the facets. Pretty easy and went quickly.

He is also going to use some cherry he picked out but instead resaw a thicker piece to go for a four corner match (I used a single longer piece so three corners match, the fourth is a little off).

I'm glad I did a prototype because I found a couple of places that are pretty easy to run into problems. I fixed one and left the other "broken" so he could see. Likewise I found one sag in the shellac this morning but left it alone also so he can see it. Fixing the sag is easy with a scraper and a touch of fresh shellac. Re-wax the side and you would never know.
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post #2 of 9 (permalink) Old 05-01-2010, 11:11 AM
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Turns out to be a very nice looking box, I think I remember seeing this in the mag, its been some time though. nice job.
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post #3 of 9 (permalink) Old 05-01-2010, 02:42 PM
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That looks great, Rob..

Check out that new high-tech cordless router.. wireless and no recharging required!!

Last edited by BigJimAK; 05-02-2010 at 02:52 AM.
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post #4 of 9 (permalink) Old 05-02-2010, 02:24 AM
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It's as sweet as it is unusual Rob, what a pity I've lost the will to use hand tools.

I see that our moderator Jim, is having the same problem as me in getting names wrong!

Harry



Nothing but heaven itself is better than a friend who is really a friend. - Plautus






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post #5 of 9 (permalink) Old 05-02-2010, 02:53 AM
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I'm lucky to get my *own* name right, Harry.. Sorry about that, Rob!

Check out that new high-tech cordless router.. wireless and no recharging required!!
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post #6 of 9 (permalink) Old 05-02-2010, 08:42 AM Thread Starter
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Quote:
Originally Posted by BigJimAK View Post
I'm lucky to get my *own* name right, Harry.. Sorry about that, Rob!
That's OK "Frank".
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post #7 of 9 (permalink) Old 05-02-2010, 11:48 AM
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Rob...

thats a fantasic setup your guild has for its members!! Wish there was something akin to that around here. Do you have any information on how it got started?

thanks
Bill
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post #8 of 9 (permalink) Old 05-03-2010, 10:19 AM Thread Starter
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Rob...

thats a fantasic setup your guild has for its members!! Wish there was something akin to that around here. Do you have any information on how it got started?

thanks
Bill
As I understand things, about 25 or 26 years ago a bunch of old-farts just started meeting in a church basement.

Eventually, they set the guild up as a 503(c) non-profit and that allowed them to start a growth path. Now the base membership is well over 400, with an average of around 120 at a meeting depending on the program/lecture/demo scheduled.

The web site is:
Kansas City Woodworkers Guild

And I think you can go here to see a bunch of archived newsletters:
Kansas City Woodworkers Guild

p.s. Bill, we have some lists for contact info at other guilds across the US. I'll ask if they have anything for Pennsylvania.
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post #9 of 9 (permalink) Old 05-03-2010, 07:00 PM
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Thank you Rob...

I got your message and the info....

Very nice web site btw...

Bill
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