Shaker Oval Box Starter Set (John Wilson)

[John Morris]

Came home from work Thursday and found a wonderful box full of goodies for making Shaker Oval Boxes. I ordered this starter set to learn how to make the boxes, from John Wilson box maker.

It includes everything to get started from the water pan to bend the bands, to the forms to make box sizes from #0 through #4 and the copper tacks, the finger templates and a few more items to get started. I have Mr. Wilson's books that I purchased previously and enjoyed them so much, and I completely enjoy the man as well, I decided to go one further and acquire the set to get started.

 

Home | Shaker Oval Box

WWW.SHAKEROVALBOX.COM

 

My goal is to learn these sizes, then as I progress I'll make my own forms and finger patterns for the larger size boxes.

Any competent woodworker can create this kit on their own, but the reality is, I do like supporting a craftsman when I can, when funds permit it, and since I have came to know John Wilson through his books and videos, I like the idea of giving him my business anyway I can. Thanks Mr. Wilson!

 

I'll build oval boxes along with my chairs and stools and other Shaker crafts and other items as well, and someday I'll get good enough to hopefully supplement our retirement when the time comes.

I'll keep ya'll abreast of my box making progress.

 

[Gerald]

Looking forwar to seeing what you do with this.

[John Moody]

That’s cool John. Can’t wait to see the boxes you turn out. 

 

 

[HandyDan]

I have been intrigued by that craft but have never indulged.  Looking forward to seeing your endeavors.

[Thad]

I look forward to seeing how these boxes come out.

[Cal]

I too look forward to your results.  And good on you for wanting/doing your part to support craftsmen like John Wilson.

[kmealy]

I've taught several classes in this and made over 150 of them.  Boxes, baskets, trays, etc.   Let me know if you have any questions.  One thing I learned the hard way:  My middle daughter graduated from Sycamore High School.   I was going to make 10 or 12 of them out of quarter-sawn sycamore (wonderfully flecked wood) for her and her best friends.    Sycamore doesn't bend for anything.   I think I got one side done without it exploding.   So the tops only were sycamore.  I suggest you start with a #2 size -- they are large enough to not have severe bending  and small enough to handle easily.

[Gunny]

Should be a interesting experience.  Keep us posted on your progress.

[John Morris]

Thanks all, and @kmealy, John Wilson suggested the exact thing regarding the #2. Thanks for that, you betcha I'll be yanking on your chord for advice and tips!

[John Morris]

On 6/14/2019 at 3:51 PM, kmealy said:

I've taught several classes in this and made over 150 of them.  Boxes, baskets, trays, etc.   Let me know if you have any questions.  One thing I learned the hard way:  My middle daughter graduated from Sycamore High School.   I was going to make 10 or 12 of them out of quarter-sawn sycamore (wonderfully flecked wood) for her and her best friends.    Sycamore doesn't bend for anything.   I think I got one side done without it exploding.   So the tops only were sycamore.  I suggest you start with a #2 size -- they are large enough to not have severe bending  and small enough to handle easily.

 

Ok Keith, so I started with the No. 2 and was pretty successful, the only thing I did wrong was undersize my dril bit to the tacks I was using and got some splitting, but I think I recovered well from that. I had ok luck with the No. 3 but I screwed up by squeezing the box band too tightly for whatever reason and it split, but I went ahead and wrapped it anyway and I glued the split back together.

Yesterday I tried a No.1 and No.4 and both cases the box band blew out, I had horrible grain run out it appears, or I didn't soak the bands long enough not sure, but I have not built a flawless box as of yet in my 4 attempts

 

I got the splitting under control, I know what I did wrong there, but any advise on the breakage of the bands? Can grain runout have an effect, or am I not soaking them long enough? Thanks

 

My first box turned out pretty good, but the top band split and I had to glue it back together by sandwiching it between a couple box forms.

 

 

 

The No.1 form inside the No. 2 box just for scale.

 

 

I had to glue and sandwich the No.3 box because I split the box piece while handling. Such a dufus I am!

 

 

Boiling a couple bands.

 

 

The tacking anvil. Actually I tried the horn of my real anvil and it worked really well too.

 

 

I am hopefully making all my mistakes on this batch. Long story short, I blew up my No.1 and 4 boxes, I believe they are just done, basically I broke them. My No.2 and 3 boxes are salvageable and I think I'll get some nice looking boxes from those two, I am really gun shy right now, not looking forward to trying the No.0 small box.

[Grandpadave52]

Keep at it John. You'll get there. John Wilson made it look so easy but I'm guessing he had a few SNAFUS in the beginning too. The great thing from all this is you're back working in your shop.

[John Morris]

38 minutes ago, Grandpadave52 said:

Keep at it John. You'll get there. John Wilson made it look so easy but I'm guessing he had a few SNAFUS in the beginning too. The great thing from all this is you're back working in your shop.

Thanks Gramps, that is most important isn't it? Back in the shop

I gotta tell ya, nothing like a seemingly simple process that blows up in my face to get humble right!

[Al B]

You're doing great John.  Practice makes perfect. I never tried bending like this. I always remember watching my uncle steam white oak bending planks when he built his boats.

Edited December 31, 2024 by Al B

[John Morris]

5 hours ago, Al B said:

You're doing great John.  Practice makes perfect. I never tried bending like this. I always remember watching my uncle steam white oak bending planks when he built his boats.

Thanks a lot Al, this is the very first time I've boiled to bend, I am pretty good at steam bending, but this boiling stuff is different. I bet you got some pretty good stories about that boat building uncle of yours!

[kmealy]

Looking back on this old topic, a couple of things to add:
* If you get splits like that, you can produce a lower level box (or tray) by cutting off the damaged part.

* I always just used a pipe clamp, clamped over the workbench and a few inches sticking out as my anvil for nailing

* When the company that made the brass nails decided to quit making them, John bought the machine and became the sole source of them

* John passed away recently, but as far as I know, his associate has kept the business up.

[kmealy]

when life gives you lemons, you make trays

Edited January 1 by kmealy

[kmealy]

In addition to the oval boxes, you can make what they called sewing boxes with a swiveling handle

 

or just a basket

 

[Zack]

You just never know what you’ll find when you start scrolling through these threads.

[John Morris]

Welp, nothing like Keith's beautiful boxes but I'm still experimenting.

 

I think part of the reason my boxes were breaking when I tried to wrap them around the forms, is I had the water box across the shop, and by the time I'd pull the wood out of the boiling water and walk over to the form it cooled down quite a bit. Also I don't think my burners were getting hot enough to get the water over 180 degrees because it was plugged into an extension cord, so I moved the box over near a receptacle for max power.

Also I set up a table right by the water so my wood can go from the tray to the form in a couple seconds.

This No. 3 box was a complete success, and it's nailed off and the top and bottom forms are in place for a couple days. Not shown  I also have the lid band over the box. 

 

While this one is setting up I finished the other No. 3 box I started last week. 

I cut the bottom out with the bandsaw and disk sanded to the line. I love my ShopSmith still

I used the horizontal boring feature for drilling holes through the side to the solid wood bottom. I set the drill up and I simply pushed the lid of the box into the bit.

Then next is the box itself.

Then I pegged the bottom to the box and the lid.

And now I have a couple boxes I'm pretty proud of right now. 

That's a No. 2 box inside the No. 3  you can't see it but that smaller box really has some issues I need to fix and disguise, it's not ready for prime time, it was my first box.

The No. 3 box I assembled today will be ready by Monday, so I'll have two No. 3's. One each for both my daughters, they both have birthdays this week. 

Thanks for following along!

[Grandpadave52]

Glad you're getting shop time John. Envy you.