Well the historic wood pen turning project is moving along, slowly, but moving. Part of the deal was to make two special presentation boxes for those responsible for securing monies. The main turner involved doesn't have many wood working tools so the box making fell on me. No one had a plan as to what they wanted the boxes to look like.

 

OK, I've made some boxes but I don't feel my skills are really up to what I think they should be for this type of project. Especially with this precious wood.

 

 

My original design was to have the box larger, but the size of the beams and the number of defects, cracks and nail holes reduced it to around 4" x 7"x 1.5". The pieces are 1/4" thick.

 

 

 

 

The old pine is very brittle but it still contained a surprising amount of sap. The number of knots would not allow me to use the planer and get this thickness, so I used my thickness sander. I had to clean the belt 3 time during the thicknessing process to remove the built up pitch.

 

 

All of the dovetails are hand cut using a Japanese pull saw.

 

 

 

 

 

 

 

The above picture show one of the "hinges". I used tiny cut nails salvaged from the original structure placed into pre-drilled holes. Right now they are just finger tight.

 

 

The lid lift is also a little nail. I think this one has to be in a little deeper. I hate it that the round hole shows on the front.

 

 

 

Although you can't tell from this picture, the bottom is thicker than the dado it fits into (bottom = 1/4" dado = 1/8"). About an inch of the perimeter is tapered to the edge allowing the fit.

 

 

 

 

I'm not sure what to do with the inside. Maybe a couple of "U" shaped risers to hold the pen off of the bottom. Covering the interior would make for a nice contrast but it almost seems sacrilege to hide the patina.

 

 

 

At this point, I am stumped on my next step. My original plan was to inlay a "Carpenter's Mark" in the outside of the top. I made an oval inlay pattern and cut a sample from some Poplar to see how it would look-

 

 

 

I made certain I salvaged all of the carpenter's marks, before I made the pen blanks from the beam.

 

 

 

Now, the problem. The pine is so brittle- even more so near the surface, that I fear the router inlay kit will splinter the the wood. To help strengthen the "mark", I covered the back of the piece with painters tape and saturated it with thin CA. I'll need to stop at Hobby Lobby tomorrow after school and pick up another bottle- thank goodness they send me 40% off coupons every week!

 

 

So that's where I'm at, with this part- still needs more sanding!

 

I was thinking about making the second box with a "pencil box" sliding lid.

 

 

Hmm I can't help much with the nails etc. but I definitely would go with the U shaped risers.

Very cool Lew!!! I love the history behind this project, and the way you are doing it is really artistic and unique, great job.

 

Those dovetails are sweet!!! You never told us you could cut clean DT"s!!!

 

 

Hey Lew, the hole for the nail handle, you are right, it is unsightly. Here is what I would do, create a wood dowel or plug of a contrasting color and plug the hole back up.

 

 

Then, file your nail shaft round only up to the point that the nail will stick out from the surface, so if you have an inch of nail buried in the lid, then just file that inch round.

 

 

Then drill a hole the same size as your round nail shaft and insert for a nice clean look.

 

Cool project Lew. I have a question. The hinge for the lid seems a bit vulnerable to me. Is that an optical illusion?

Neat box, Lew.

John beat me to the nail fix.

 

For the inlay, you could scribe around the oval. Less splintering that way. Or, cover the lid with masking tape before you rout.

 

 

Thanks for all the comments and suggestions!

 

Ron, VERY fragile. This box and pen probably will never actually get used other than for a display, so I've got my fingers crossed it will last. Another reason for opting for a sliding lid in the next one.

 

 

Bringing up yet another great project from our archives.