Box making Curved Front Box #14: Starting the internal trays

  • Advertise with us
Blog entry by robscastle posted 11-26-2013 07:17 AM 1422 reads 0 times favorited 5 comments Add to Favorites Watch
« Part 13: The trim drives me nuts or more frustrating errors Part 14 of Box making Curved Front Box series Part 15: Completion and Dry fit up of the Trays »

Today I started the design and build up of the internal trays.

The overall concept is two trays the lower the deepest with central dividers to allow easy removal.

After doing some sketches and trying to determine a practical solution it was back to cutting curved profiles for the fronts.

I wanted to avoid this process and use kerf sawn curved sections, but my inexperience in doing timber 10 to 12mm sections saw me returning to cutting the fronts on the bandsaw.

I wanted to avoid having to veneer the trays but did not have enough stock to use NG Rosewood all round.

So it will be more veneering of the front and top of the trays at least.

I also was wanting to step back from veneering mainly due to the tearout I was experiencing.

The reason for this is not that it will not happen again but the apparent inability to be able to buy Hot Hide Glue and its associated accessories in Brisbane.

It seems that you can buy the Glue no worries but the brushes glue pot and other components are not available any where.

So my thoughts were to avoid veneering until I can repair any damage reasonably easly rather than have to resort to chiselling out Titebond glue, the glue is great don’t get me wrong, but not if rework is required like veneer chip out.

Anyway back to the tray work.

I screwed together enough jointed stock to do both trays, and then cut the first profile on the band saw using my cardboard profiles.

Once I made the first cut I realised it would be best to sand both together before separating,
So an additional oscillating sander step occurred before both were then cut out as individual fronts.

It was then on to determining the grain layout for the NG rosewood I wanted to use on the sides and back.

Enough prattle here are the results in a reasonable sequence.

The front stock jointed and ready to cut

The first cut completed.

The NGR Frame work layout.

The grain layout was my primary concern so I laid out the tray to allow the grain to run continuously from the front side to the back and complementary side.

Now cutting rebates on curved timber was another brain teaser for me.

How I did it was a fairly simple solution, I used my drop saw with a preset depth and a backing board as a guide.
Simple eh!!

Next process will be dovetailing the back to the sides and then matching the sides to the front section for fit .
I am thinking rebated butt joints. Lets see what evolves!!


-- Regards Rob

5 comments so far

View stefang's profile


17040 posts in 4418 days

#1 posted 11-26-2013 09:45 AM

Looks good Robert.

-- Mike, an American living in Norway.

View shipwright's profile


8716 posts in 3882 days

#2 posted 11-26-2013 03:05 PM

Good progress.
Don’t count on HHG to be a lot easier to repair. Yes it is reversible, but it isn’t as easy as you might think. A better approach would be elimination of the chip out in the first place. HHG will help there as you can repair any poorly glued areas with an application of heat from an iron or hot caul. Hammer technique will also help get the edges glued well.

-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese!

View David Dean's profile

David Dean

608 posts in 3983 days

#3 posted 11-26-2013 05:41 PM

nice work and it’s all old school to.

View BobWemm's profile


2971 posts in 3010 days

#4 posted 11-26-2013 11:54 PM

Glad it’s you and not me, Robert. I would have tossed it by now. LOL

-- Bob, Western Australia, The Sun came up this morning, what a great start to the day. Now it's up to me to make it even better. I've cut this piece of wood 4 times and it's still too damn short.

View robscastle's profile


7878 posts in 3288 days

#5 posted 11-27-2013 01:17 AM

Thanks Guys, its the encouragement that keeps me at it
It has got to be the longest and frustrating of my projects.

Just how did craftsman make these years ago, possibly just two saw horses for a bench and with non electric tools for sure, makes you wonder.
I remember as a young boy my Mum had a curved glass fronted cabinet in our lounge room, its construction was always fascinating with its curved timber and glass as well.

-- Regards Rob

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics