Pretty tools and boxes, Part 3

Continuing the saga.

I'm making 3 boxes, so I turned 3 "stencils" into 3 "trays" by gluing a piece of plywood to the bottom. It doesn't matter what this all looks like right now because it will be covered with flocking (received the Kelly Green flocking stuff and I think it's going to look nice). Also, I realized that the "chipout" of the plywood can be fixed with Bondo, ground, and sanded....since it's going to be covered up with flocking.

Next is to make the boxes, which will be made like a sandwich. I'm going to start with the filler and then work on the bread. The filler is 4 pieces of wood glued up into a rectangle. I want this to be just a little thicker than the thickness of the "tray" and the thickest tool, which is the tape measure. I started with 2 inches but will reduce that down later. All of the wood is rough cut, air dried lumber. There are many steps in rough cutting, planing, truing, etc until it is useable, and all of this is repeated for the 12 pieces for the 3 boxes.


All parts are milled down to 1/2 inch for lightness, then cut to size and glued into the rectangle.


Then the tray is cut to fit into the box and fastened in place.



Next I milled the wood to be used as the "bread" (top and bottom). These have been glued up into small panels and now I have to cut them to size.


After these are glued on the boxes will look rather like cigar boxes that cannot be opened. They will be passed through the saw on all 4 edges to separate them into box tops and bottoms.

More to come.