(In the) Court of the Crimson King #3: The outer shell

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Blog entry by BritBoxmaker posted 10-01-2012 03:59 PM 6932 reads 4 times favorited 12 comments Add to Favorites Watch
« Part 2: Lets get this party started Part 3 of (In the) Court of the Crimson King series no next part

This is the interesting bit. First the top, the easier part?!

I cut the centre sections out of the four Padauk strips. Book matched them, mitred them and glued up the above square. Yes I know theres a hole in it. I forgot to take the picture before I started the ‘boring’ bit.

Here’s the padauk top square with a pattern on it for centres of holes which are at the innermost part of the top slots. I could have done it by hand but as the plan was already in CAD I just printed off the relevant layer and glued it on (Pritt stick, stuff they let kids use to stick paper together with).

Centre punched the centre of the crosses and bored each kole out to 6mm, using a Forstner bit in the drill press.
Why do it this way?. Well the next item should make that more apparent. My jig for holding the top whilst I routed out the slots.


and bottom. The dowels are 6mm, 56mm apart, and are used to hold the top so

Next to the router table to route out the first two slots


Routed from the outside to the inner hole on both sides. Held very firmly and advanced very slowly so as not to let the 6mm router bit snatch the piece. The first two slots done you just rotate the top around to the next two, route them and continue until all twelve are done. The jig grips against the inner of the pre-drilled holes for all of them. When finished you have this

The top then drops over the centre of the board to show this

Trial line ups of the side pieces showed I was on the right track

Now the ‘clever’ bit. The top is a very delicate flower and even glued to the base board I could forsee bits flaking off under EZ Mitring. So I pre-mitred the ends of the sides and the top on the belt sander. Table set to 45°.

Using a board under the top piece to stop anything flying off it. When placed together , upside down here, you get this

With all side pieces arranged aound the outside

The side pieces were then cut in half longitudinally and the sloped edges routed along them using a 60° router bit.

Close up

The top and side parts were glued onto the base board to give this

A couple of coats of spray acrylic

and corner pieces added in to steady the EZ Mitre routing

Sides trimmed off to length

Then mitred and glued up

There were furry ends to the coloured veneers, these cleaned up well with a scalpel to give a nice clean edge though. The pedestal base is as described in the Shell box blog so I won’t go into that here. Thats it basically..

The finished box is posted here.

Be seeing you.

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

12 comments so far

View Jamie Speirs's profile

Jamie Speirs

4168 posts in 3907 days

#1 posted 10-01-2012 04:20 PM

Martyn that is incredible

the planning is just feat on it’s own.


-- Who is the happiest of men? He who values the merits of others, and in their pleasure takes joy, even as though 'twere his own. --Johann Wolfgang von Goethe

View Roger Gaborski's profile

Roger Gaborski

341 posts in 4798 days

#2 posted 10-01-2012 04:32 PM

Thanks for the detailed instructions. Another great box.

-- Roger

View SPalm's profile


5338 posts in 4932 days

#3 posted 10-01-2012 04:49 PM

Clever one you are.
Very nice Martyn.


-- -- I'm no rocket surgeon

View BTimmons's profile


2303 posts in 3535 days

#4 posted 10-01-2012 05:48 PM

You’re a madman, for sure.

-- Brian Timmons -

View bibb's profile


332 posts in 4581 days

#5 posted 10-01-2012 06:21 PM

Your problem solving skills are amazing!

-- you may only live once, but if you do it right that's all you need

View woodklutz's profile


221 posts in 3818 days

#6 posted 10-01-2012 06:59 PM

Martin, as said by everyone”Just Fabulous”
p.s. I will not be attempting this.

-- honing my craft one mistake at a time.

View Sodabowski's profile


2399 posts in 3883 days

#7 posted 10-01-2012 07:14 PM

What Jamie said, most of all.

Your approach to routing the channels is very clever :)

-- Thomas - there are no problems, there are only solutions.

View Roger's profile


21054 posts in 3854 days

#8 posted 10-01-2012 09:23 PM

Martyn, you are a box magician. Wow! Very kool

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

View BertFlores58's profile


1698 posts in 3972 days

#9 posted 10-01-2012 09:41 PM

Mitering with those slots without the colored strips will be quite difficult as there will be nothing to hold it. Thanks for the idea. I can use this technique in lamination with acrylic combine with wood. Mind bodering.. that will keep my mind doing another designs.

-- Bert

View gfadvm's profile


14940 posts in 3740 days

#10 posted 10-02-2012 02:05 AM

Martyn, You have an amazing way of coming up with solutions to insurmountable problems. Mitering the top with the belt sander was genius as was the ‘holder’ for routing the top. I learn something every time I click on Brit Box Maker!

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

View Sheila Landry (scrollgirl)'s profile

Sheila Landry (scrollgirl)

9239 posts in 3970 days

#11 posted 10-03-2012 07:26 PM

Very cool, Martyn. Watching this process is so interesting. Thanks so much for taking the time to document it for us. :)


-- Designer/Artist/Teacher. Owner of Sheila Landry Designs ( Scroll saw, wood working and painting patterns and surfaces. "Knowledge is Power"

View mafe's profile (online now)


13065 posts in 4139 days

#12 posted 10-05-2012 04:38 PM

Clever, Martyn, clever.
Really a nice effect with the deepth in the wood.
Best thoughts,

-- MAD F, the fanatical rhykenologist and vintage architect.

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