A personal challenge - The make #5: Day 5 . Much trepidation!

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Blog entry by BritBoxmaker posted 05-09-2010 04:42 PM 2699 reads 2 times favorited 9 comments Add to Favorites Watch
« Part 4: Day 4 Part 5 of A personal challenge - The make series no next part

Hello all this has been the most fraught day of this make and the most exhilarating. The cramp from my arm died down after about the fourth beer so I wasn’t too bright this morning when I started again.

However I set about making the border for the top. I cut each piece roughly to size, with a knife. Like cutting matchsticks. Then shaped the mitred ends on the disc sander (180 grit disc).

You can just about pick out one of the side pieces nearest the disc on the lefthand side. Before long I had all the pieces done

Gluing together was done, as was most of the construction, under my magnifying lamp

When this was finished I cleaned it up very very carefully on the belt sander (180 grit belt). I cleaned the top of the sides up on this too and the stuck the box and top together. Shaky hands. Cup of tea. Good talking to myself then action. Result.

After cleaning up on the belt sander and a coat of sanding sealer

My guts churned. This was the moment of dread. So kean was I to get it over with I didn’t even take pics of the box seperation. Within minutes I had cut most of the way through all four sides on the tablesaw leaving only the teasing apart of the two halves, back on the bench with a knife.

To reveal

Most of the rest seemed to fly by. As you can see above I cleaned up both box halves. I then cut and fitted the lipping in the bottom half. Cleaned it all up with 240 grit. Applied sanding sealer, with a cotton bud, to the insides of the box. and polished it.

As you can see I didn’t clean up the inside of the top. The top was starting to get a bit thin anyway and doing this would have ruined it.
Please excuse any crumbs of white dust. At this scale they appear enormous. Suffice it to say I have now finished. That is both the box and I are finished. I need a long lie down.
I hope you have enjoyed this oddessey into the realms of scrap box making. I certainly have


As promised I will now post this as a completed project.

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging.

9 comments so far

View tyskkvinna's profile


1310 posts in 3349 days

#1 posted 05-09-2010 04:55 PM

wow! that looks great. :) I was wondering how you were going to handle the separation/lid. Now I see.

-- Lis - Michigan - -

View BarbS's profile


2434 posts in 4448 days

#2 posted 05-09-2010 04:58 PM

Martyn, that turned out to be quite a challenge! And in miniature, always daunting. I think you should scratch “LJ’s” into the bottom of it and save it as a friendly reminder of guiding us all through your oddesy (sic). It is a beautiful bit of ebony and color.
And thanks for the procedures, most of all! I had forgotten about cutting a window to move over a pattern, seeking the best cut out of it; read too long ago. I learned a few things here from your project, and I appreciate your guidance. Have a good rest!


View Dennisgrosen's profile


10880 posts in 3478 days

#3 posted 05-09-2010 06:18 PM

beautyfull miniature you have done
thank´s for sharing this journey with us

a very informative blog, you do a great job with them

Thank´s Martyn

View SPalm's profile


5332 posts in 4245 days

#4 posted 05-09-2010 11:10 PM

Well done sir. A right handsome box.

My hat is off to you,

-- -- I'm no rocket surgeon

View BritBoxmaker's profile


4611 posts in 3399 days

#5 posted 05-09-2010 11:16 PM

Why thank you sir.

I don’t have a hat, but imagine me returning the favour.


-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging.

View Cozmo35's profile


2200 posts in 3398 days

#6 posted 05-09-2010 11:55 PM

Martyn, I applaud till my hands are numb and my feet hurt from standing! WOW, great job! I really enjoyed this blog!

-- If you don't work, you don't eat!.....Garland, TX

View Mary Anne's profile

Mary Anne

1058 posts in 3571 days

#7 posted 05-09-2010 11:59 PM

I have thoroughly enjoyed this tutorial and learned so much… including that I should leave the miniatures up to you! :)

View BritBoxmaker's profile


4611 posts in 3399 days

#8 posted 05-10-2010 12:01 AM

You don’t do things by halves in Texas do you, Cozmo.

Many thanks and again glad you enjoyed it.


-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging.

View lumberdustjohn's profile


1263 posts in 3529 days

#9 posted 05-10-2010 02:29 PM

Amazing what can be done with such small pieces of scrap.
It’s was hard enough for me to throw away small pieces…8 inches long.

Thanks for the blog.

-- Safety first because someone needs you.

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