With the box construction complete, it’s ready to be finessed. Paul refines the shape of the feet, and scrapes and sands the surfaces in preparation for applying a finish. Shellac is then applied with a brush for an even, durable finish. The last few finishing touches are to fit a stay, in this case using epoxy, and fit a leather lining in the bottom of the box.
Paul fits the optional divider to the inside of the box before laying out the hinging. The hinges are fitted to the lid, then onto the main body of the box, with care taken to transfer and align the hinges. You may need to make some micro adjustments for alignment of the lid. With the box back together, the joint lines and overall shaping of the box can be refined. Then Paul carves out a small finger recess and cuts and fits some feet.
Once the rehearsal and dry run is done, a few adjustments can be made before rounding and beveling the rims of the lid and base. Then it’s time to glue up, ensuring tight joints. Once the box is cleaned up, it can be sawn in half before the joining edges are planed.
The next step is to size the top and bottom in preparation for cutting the grooves and rebates in their edges. Paul uses a cutting gauge to minimise damaging the edge when using the plough plane. The rim is planed before the sides and ends are grooved to receive the lid. Then the optional housings for the divider can be cut and the sides can be rounded. The final step before gluing up is to cut the pins flush with the main body of the box.
Paul explains the joinery used on this keepsake box, before discussing stock choice. Then the dovetail recesses are cut in order to align the dovetails for layout and cutting.
Paul introduces a brand new design. This highly defined and refined keepsake box features curved sides with stepped and angled dovetails. With its floating panels, top and bottom, which are fitted into grooves, Paul created the dynamic allowing for expansion and contraction. This might make it seem a complicated project, but Paul takes you through it step by step to make an heirloom piece. It can be scaled and customised for a variety of uses.