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My wife is a pianist so I decided to make her a piano box for Valentine's Day. I again used the willow burl I salvaged from a stump the city cut, down the street from my house. The whole thing is carved/routed from a single solid piece of wood. The piano keys are made from moose antler and the black keys are black walnut.

I started by drawing the outline of a piano to scale on a piece of hardboard which I then cut out with a jigsaw and attached to a piece of the burl wood with superglue. I used a 1/4" router bit to hollow out the edges and a 1/2" bit to hog out the rest to around 1 1/2" deep.



To form the legs I used the bandsaw where practical and a coping saw where not to remove the bulk of the wood.



Next I took it to the router table to clean it up. Once I got the legs close to where I wanted them I used a belt sander and sanding block to do the final shaping.





To felt the inside I masked everything off and applied spray adhesive to both the box and the felt and pressed them together.



The keys are made from a piece I cut from a large chunk of moose antler. I marked an arbitrary spacing on the combination square and used it to score the antler at regular intervals with an exacto knife. For the black keys I used some scrap black walnut and a chisel to get a general size, then used tweezers and a sander to get the final shaping.



After sanding down to 1000 grit with 2" rotary discs I used Danish Oil to make the complex grain in the wood really pop. I feel it turned out really well and the wife loves it. Another treasure made from an ugly piece of salvaged wood. Thanks for checking it out and reading my story!



Gallery

Comments

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56 Posts
very cute box and some really nice burl.
 

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520 Posts
Nice work! Beautiful wood.
 

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6,567 Posts
That burl is awesome. Putting it together as a piano was neat. Thanks for the pics of the journey.

I imagine the Wife liked it?
 

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3,100 Posts
Very nice job, the burl wood is beautiful. I bet your wife did love it!
 

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Wife did indeed love the piano box. Thanks for the comments.
 

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1,403 Posts
Cute, and impressive.
 

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Excellent use of a salvaged piece of figured Willow wood. Very impressive. Thanks for sharing the steps in building it.
 
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