LumberJocks, The Community Creates a Memorial in Mark's memory #2: Making the shadow box frame

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Blog entry by Karson posted 02-12-2008 03:23 AM 6277 reads 1 time favorited 13 comments Add to Favorites Watch
« Part 1: I'm starting out on my part Part 2 of LumberJocks, The Community Creates a Memorial in Mark's memory series no next part

Well Dusty and I talked about the broken and fractured stained glass panel. The panel was insured for material costs but definitely not the 70 some hours that were taken to make the panel.

Previous blog Dusty’s #5 starts here. First blog starts here.

I didn’t start on making the frame for the stained glass panel because I wanted to make it to fit the actual glass panel.

Since we had a delay. The breakage and the filing for the insurance claim, I thought that I’d make the frame to match the size of the one that I received. We originally talked about a 24” X 24” panel but when it arrived it was an 18” X 24” panel so I’m glad that I waited on that.

I had been waiting on the new tools that I had ordered. A Foredom Power carver from eBay and a Stewart MacDonald router that fits the Foredom hand piece.

They both arrived about the same time. The Foredom is a motor drive, in my case 1/6 hp. It transmits its power through a flexible shaft to a hand piece that holds an assortment of router and grinding bits.

The kit came with two different hand pieces. I bought another one with the router base. It screws into the router base instead of using a Dremel tool.

The router base arrived also; it has the modified Foredom hand piece installed.

I took the picture that Dusty sent me,

I printed it out at 25% and got a print about 1” x 1 ¼”. I taped it unto a sheet of 1/8” Lucite.

I then cut it out.

I used the cutout to trace the Dove unto some ¼” thick Holly wood.

I then cut out 5 of them to be able to play around.

About a month ago I bought some used/resharpened router bits on eBay. There were 10 1/32”, 15 – 1/16, 15 – 3/32, 10 – 1/8” a total of 50 bits for $25.00. At the time I wasn’t sure I’d ever use them, but it was a good buy.

I put the 1/32 bit in the router.

The router bit is lowered in the base where the taper of the bit shank rubs against the plastic pattern. That causes the cutter to not cut into the master pattern.

The master is held on the Sapele with double face tape.

I used the router bit the cut out the entire void of the patters. I just kept going back and forth and removed all of the wood. It was easier to go around the edges when the center was removed. Depending upon the grain pattern, I sometimes went clockwise and other times counter clockwise. The hole was about 1/8” deep.

So I got both of the inlays cuts cut out.

To make the inlays fit in, I used a sander in the Foredom, and a knife and a chisel to enlarge the cut in the Sapele.

When I cut the inlays out I cut outside the lines so I knew that they would be oversized. It took about 30 minutes to trim it down and to enlarge the hole to make them fit. Now when I say fit, it means the lower edge was cut enough so that it would fit into the void. It was somewhat of a taper fit. But mostly close all the way around.

I then filled the void with 5 minute epoxy.

I set the dove into the void.

I then put the package into the vise and pressed them home.

The inlay was about ½ in the wood and the other half above the surface.

After pressing them home I beveled the edges with a sanding disk in the Foredom hand piece.

To make the shadow box, I wanted to make something that would be stable. I was concerned about a 45 deg angle joint. I then remembered a router set for making joints that I bought from Woodline. I bought it at a woodworkers show. It had different joints. I went with a gentle loop.

The other cut is made with the wood in an upright position.

The joint looks like this.

I cut all four sides from the same board so that the wood grain and color would match. It’s made from Sapele that I got free from the window mfg. They were cut using a resaw blade in my bandsaw.

I then glued it up.

When I made the face frame with the inlays, I made them long so that I could figure out where I wanted the placement. When I placed them in front of the glued up frame liked the high placement of the doves.

I placed the shadow box over the broken picture and then placed the inlay pieces on top. I like the look and the two doves were placed facing inward and with an upward flight matching the picture that Dusty created..

With the panel in front of a window in the solarium.

It now came time to put the face frame on the shadow box.

I dug out an old tool that I bought 30 years ago. It’s called a Lion Trimmer, They were the original as far as I know. Other brands are being made and sold now.

You can see what happens when you loan your tools and they come back all rusty. I also found out that one of the blades had a knick in the cutting edge. So much for loaning tools.

I had to adjust the tool to insure that it was cutting at a true 45 deg. I cut two pieces of wood on the same knife and then placed them into a 90 degree mode and checked to see if it was true. Both sides were out of alignment.

The machine cuts like a paper cutter. It slices the wood off of the board.

When you get done you end up with a lot of slivers of wood. You can peel fine cuts off of the wood. I guess today Tom and Bob #2 would use a 45 deg shooting board and a plane to do the same thing.

The frame was trimmed to a 45 deg angle and then put in place. I used a ¼ overhang on the outside. And about ½” overhang on the inside.

A few coats of Shellac, put on with a French Polish rubber.

After the finish has cured. I started to build a transport box, to ship the frame and eventually the stained glass panel. It’s made out of a 2X6 that was trimmed down to be the exact height of the frame and 2 – ¾” Styrofoam panels.

I also burnt my built by brand into the frame. And the panel mounting clips.

The mounting clips are screwed into the frame and slid up tight to the stained glass panel.

I now filled up the inside of the box with additional foam panels and the memorabilia that will also be sent to the winner of the drawing.

Dusty has his memorabilia in there and I put in an autographed issue of Woodcraft magazine where my Baby cradle/glider was published. LumberJock contest winner #1.

Here are some additional pictures that I had failed to upload. It’s the new frame with the broken and fractured picture.

The box was all closed up with alignment marks that will allow the box to be reassembled using the same screw holes that were used in the original assembly.

It should be given to the shipper tomorrow. 2/12/2008.

God bless you Mark and to the winner of this project. It has been a pleasure to be able to work on it with Dusty.

To enter your name into the drawing for this memorial, make your donation to LumberJocks. See the LumberJocks eMagazine for information.

Here is a copy of the particular info from the eMagazine.

Memorial Event for Oscorner

Most of you are aware of the passing of our fellow LumberJock, Oscorner. Many of us were first greeted by Mark when we joined the site and we were blessed by his kind words of support when we posted a project.
Now, with the initiative of Dusty and Karson, a Memorial event has been set up in his honour. One of Mark’s requests for his funeral was that people didn’t spend money on flowers but donated them to a cause that would help others. Dusty and Karson are doing just that.

Together, they have created “Mark’s Heavenly Flight”, a framed stained glass piece of art that symbolizes Oscorner’s faith and his final journey. LumberJocks are encouraged to make a $10 donation to in Oscorner’s memory (which will ensure that the site is funded for some time, keeping it available to help others). Everyone who makes a donation will have their name “put in a hat” and a random selection will be made on February 21th. Arrangements will then be made for this person to receive the one-of-a-kind memorial piece.

The blog on this memorial begins with Dusty, moves on to Karson’s work, and then back to Dusty again. The series starts here

To participate in this tribute, make your $10 donation in Oscorner’s name. Donations for the memorial can be made here

A big thank-you to Dusty and Karson for their tribute and all the work that they have put into this.

“Thinking of you, Oscorner”
~ the LumberJocks

Do it here

I failed to identify the measurements.

18 1/2” wide by 24 1/3” high on the inside
3/4” thick Sapele wood
Face frame has 1/4” overhang on the outside and 1/2” overhang on the inside So the face frames are 1 1/2” wide.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

13 comments so far

View Grumpy's profile


25623 posts in 4365 days

#1 posted 02-12-2008 04:09 AM

Great blog Karson. Just shows you the power of friendship.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View lazyfiremaninTN's profile


528 posts in 4467 days

#2 posted 02-12-2008 04:56 AM

That frame is amazing. YOU, Karson, like Dusty are talented beyond my wildest dreams. I can only hope that with time I can get my skills close to your level.

-- Adrian ..... The 11th Commandment...."Thou Shalt Not Buy A Wobble Dado"

View Karson's profile


35202 posts in 4915 days

#3 posted 02-12-2008 05:16 AM

Thanks Guys. It’s been a pleasure to do this for such a worthy cause.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View gizmodyne's profile


1780 posts in 4604 days

#4 posted 02-12-2008 06:32 AM

Amazing work again Karson. Interesting inlay technique with the plastic. It is on my list of skills to learn. This is a great co-project. I feel proud to see this evolve.

-- -John "Do I have to keep typing a smiley? Just assume it's a joke."

View rikkor's profile


11295 posts in 4389 days

#5 posted 02-12-2008 11:01 AM

What a beautiful frame for Dusty’s stained glass. I had the privilege of seeing it in Dusty’s shop last month. With that frame it will be just awesome!

View MsDebbieP's profile


18619 posts in 4675 days

#6 posted 02-12-2008 12:02 PM

Karson, this is outstanding. The shadow box/frame is so beautiful and, just as the stained glass piece, far more than I had envisioned!!!
You and Dusty have certainly “done Oscorner proud”.

I know that there have already been some donations made. What a wonderful way to pay tribute to such a wonderful man and member of our LumberJock family.

Thank you Karson. Thank you Dusty

-- ~ Debbie, Canada (, Young Living Wellness )

View Critterman's profile


601 posts in 4324 days

#7 posted 02-12-2008 01:53 PM

Karson, what a terrific job. Love the way you did the doves they really make your eye move to the stained glass Dusty made. And like all your other work fit and finish are outstanding. Osconner would have been proud to have friends like you guys to do such a beautiful piece in his name. Way to go guys.

-- Jim Hallada, Chesterfield, VA

View Karson's profile


35202 posts in 4915 days

#8 posted 02-12-2008 03:27 PM

Updated with measurements of Shadow box and face frame.

And thanks for the compliments.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View Karson's profile


35202 posts in 4915 days

#9 posted 02-13-2008 04:41 AM

Bump up.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View Dusty's profile


785 posts in 4670 days

#10 posted 02-13-2008 04:51 AM

On rare occasion, and through our our lives there are experiences that simply defy description or meaning.

To be a part of this Memorial with all those who have shared in this project, has been one of those for me.

Certainly, a large part of this honor and privilage has come from the bond that has been formed and built working with a master like Karson.

That aside; it goes with out saying, his obvious woodworking talents are only part of the hidden quality’s he posses in his character and values as a person.

This is why I am honored to call him my friend.

His project frame speaks for it self and is in no need of comment from me.

Enough said.

-- Dusty

View Lee A. Jesberger's profile

Lee A. Jesberger

6866 posts in 4494 days

#11 posted 02-16-2008 03:29 PM

Hey Karson;

Fabulous blog. That Foredom tool with the Stewart MacDonald base is fantastic.

Thanks for pointing out another tool that I need (?)

Now I have to find the top ten reasons for buying a new tool, written by Jude Herr. My contribution to the list won’t work in this instance…

“You’re the one that says size matters. This one’s bigger”. LOL

Great inlay work!


-- by Lee A. Jesberger

View Dick, & Barb Cain's profile

Dick, & Barb Cain

8693 posts in 4814 days

#12 posted 02-16-2008 05:50 PM

Hi Karson!

A superb looking frame, I can see that you put a lot of love into every inch

of the design, & construction of it.

I’m very proud of all the effort you, & Dusty put into this beautiful memorial.

Now lets all of us make this a huge success by making a contribution.

We don’t want Karson, & Dusty’s labor of love go unrewarded.

-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN.

View Dusty's profile


785 posts in 4670 days

#13 posted 02-17-2008 01:20 PM


Thank you for all your support. Even though Karson and I built the projects there were several other Lumberjocks who have taken part in this like Douglas, Debbie, Rikor, and of course Dan Walters who came up with the idea of doing a lottery.

It goes goes with out saying that Martin had to approve and set up the fund in order for this to happen.

Several other Lumberjocks have offered support in many ways and have indicated they have donated to the memorial.

This has been very gratifying.

Karson’s frame arrived late Friday and I hope to get around to opening it up later Saturday and posting pictures and short blog entry soon.

Russel and a few others have offered if needed to be part of the chain of custody to deliver the Memorial Piece for Mark if needed.

Depends on who wins the drawing and where it is going this maybe a very viable way of delivering the piece.

I hope to open this topic up for discussion in the next blog.

Again thanks for all your support.

-- Dusty

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