Build Along - Letter Box

[Brokenolmarine]

Once the four sides are cut, you have boxes with actual tops and bottoms.  Unless you are perfect or you have some type of jig, you'll have some minor issues to contend with.

Some work with the sander and planes took care of that.  Now ready for some finish sanding and then the application of the natural oil.  First I'll need to add the last items to each box.  The guides to hold the lid center on the sewing room box, and the insert for the top for the letter box and the dividers on the bottom to keep the letters in place.  Those will wait for the next session.

[Brokenolmarine]

Got out over the last couple days, a short session here and short session there.  We have had contractors out to run power to the new small run in barn and feed room.  Took a long while to get them out.  We have been busy with that, and I had other issues, but knocked out a few things.  Drawing close to the end, so one thing I had to remember to so, was a neat little trick.... I took some black paint and painted a line down both ends of the area where the leather insert will go.  With all the tooling, it's just a fraction short.  This will prevent that bright white background from showing through.  Can't paint the WHOLE thing black or the contact cement won't hold as well.

Then I spent about two hours with small squares of sandpaper doing the finish sanding on all four sections of the two boxes.  Any blemishes were sanded away.  Not furniture, but I wanted them to look as nice as possible.   Next I cut the strips of leather that will become the index strips inside the lid to the letter box and VERY carefully stamped the letters on the strips.  They represent their positions in the box.

[Brokenolmarine]

Since I had to run to the doc about a possible ear infection that made the whole left side of my face and jaw hurt, I didn't get much done today, but I wanted to knock out the oiling of the pieces.  All four box components and the two reference strips got their first couple coats of oil.  They will dry overnight and I'll likely put a second coat on them tomorrow; AFTER I put the dividing rails in the letter box bottom between the letters, and the top between the reference strips.

The sewing box oiled, (The strips are in the pic as well.)  The grain on this box is really nice.

The letter box doesn't have as nice a grain, but the mahogany is still nice looking, and both will look good once put together.

More work tomorrow.

[Brokenolmarine]

Session this morning, now that the barn electrical project is done for the wife.

The first portion concerned the reference strips now that the oil has dried and we have a resistance coating.

I put a nice coat of antique on the strips, ensuring that every letter was fully filled and let it sit for about five minutes.  Then, wiped off the excess, careful NOT to wipe the antique out of the letters.  This darkened the natural leather and filled / highlighted the letters.  I think it turned out great.  I let it dry while I worked on the dividing strips, then put on a coat of finish.

I made two pairs of dividing strips from scrap walnut, measured to be the appropriate height.  One set for the letter tray, and a set to fit between these reference strips.

I rolled the top edges for aesthetics, and then coated them with natural watco and set them aside to dry.  We are very near the final assembly point. 

[Brokenolmarine]

Another session, assembly in progress.  Started with the letterbox bottom rails.  They will keep the letters in the proper place and order and leave a space below the letters to store the handles.

It worked out well, though I didn't like the larger stamps in here so they will live in a tray in the leatherwork bench drawer.  I don't have that many at this time, so no biggie.

Next up was making sure I oriented the under side of the top correctly then assembled the reference strips and spacers for that... They turned out very nice, and the walnut strips accent the antiqued letters on the strips perfectly.

[Brokenolmarine]

Next up, I glued in the inlay for the top of the letter box.  It's coming together.

So this is what you would see when you open the box, once I actually get hinges and a latch for the thing installed.  You have the letters and such in the bottom, and the "Box of Chocolates" reference in the lid.  I am pretty happy.

The closed box is pretty attractive with the grain matching up and looking pretty good.  I may have to use my syringe and needle combo and inject a touch of glue under that top inlay.   There may be a touch of an edge rolling up just a tad.  OR, it could just be a shadow.  I put pressure all around the edges to set the glue.

I got Miss T's sewing box top inlay in the clamps before I finished that session, and her box is almost done as well.  That one will have some awesome grain.

[Brokenolmarine]

Went out this morning and looked thru the available hinges I had, and nothing that fit, looked like it would handle the weight of the mahogany lid.  So, I took a three foot section of brass piano hinge on hand, trimmed it to length, rounded the end corners and Boom.  Hinge.

It works well and should last a long time.  The box is done and other than a coat of wax now and then will be a working addition to the leather bench.

I moved on to Miss Tina's sewing box, and formed the guides that will center the top when she removes and replaces it each time.    I have them glued in place and am waiting for the glue to set.  Then I'll oil the walnut and take some pics.  Her box will be done, other than a couple coats of beeswax as well, then on to the next project.  Scabbard?  Gunbelt?  Knife? Who knows, something to keep busy.

[Chux]

That is very nice!!

[Brokenolmarine]

Back out to finish Miss Tina's sewing room box.  The glue had said, and a coating of oil was applied to the whole box.  Can you say, Ooooh...   I love it when a plan comes together. 

 

In the picture below, you can see the walnut guides attached to the inside edges of the bottom tray.  The ensure the top will be in proper position when Tina puts it back on.  It will only go one way, all she has to do is match the grain pattern on the front if she mixes up the top and bottom alignment.

 

She really loved the box, and said the beautiful grain in the spalted maple really compliments the grain in the mahogany.  Now both boxes are complete other than a couple buffed out coats of wax.

Most of my projects are started with a basic idea, and done on the fly, with the planning done as I go.  I love the flexible work and the freedom it gives.  I can work from the templates or rigid plans, but had to for my first career, and enjoy this so much more.  Color this one done.  On to the next.... 

[Brokenolmarine]

Last work on the project.  Went out this morning and applied a good coat of wax to the wife's sewing room box.  It glows softly and looks good.  I'm done.

I like the grain and contrast on her box even better than the letter box.  I'm jealous.   But then, shouldn't the boss get the nicer things. 

[Gezzer]

VERY NICE work on both boxes and thank you for taking me along on this build !!!

[Brokenolmarine]

You are all welcome to comment, helpful critiques are appreciated. 

Thanks to those who have....

jim