Page 1 of 2 12 LastLast
Results 1 to 10 of 15

Thread: Music/Jewellery Box made from Cherry and Walnut

  1. #1
    Join Date
    Oct 2006
    Location
    Toronto, Ontario, CANADA
    Posts
    2,332

    Music/Jewellery Box made from Cherry and Walnut

    (part 1 of 4)

    Today is my oldest (living) grandchild's 10th birthday and I made her (Isla) something special to mark the event.

    The item is a small jewellery box that contains a music-making mechanism made in Switzerland. The music that is played is 22 notes from Lara's Theme.

    I will describe the making of this box using extracts from my weekly journal.

    2009, Nov 29:

    I started another project this week. This time it's a small music/jewellery box for Isla's birthday in January and the plans come from the same issue of Wood magazine as the table that I am making for Margaret. Here is a picture from the magazine: Click image for larger version. 

Name:	Music box 00 -Photo from magazine -small.jpg 
Views:	42 
Size:	112.5 KB 
ID:	41508

    The box in the magazine is made from mahogany and maple. I am making it from cherry and walnut. The actual music making mechanism suggested in the magazine is one from Rockler costing about $20 and made in China. A couple of months ago, I ordered two different mechanisms costing about $100 each and made in Switzerland. They both play Lara's Theme. I will use the better sounding one in the box.

    Dec 13, 2009:

    I carried on working with the jewellery/music box this week. The one that I am working on right now will most likely just be a prototype that I will not give to anybody and that, in the end, will not have any music mechanism permanently installed. I decided to try inserting small dowels into the two 45 degree mitered corners at the front of the box. This is not something supported by the Dowelmax jig parts, so I made an extension to the jig out of plywood to enable drilling into the facing faces of a 45 degree joint:
    Click image for larger version. 

Name:	Music box 01 - Dowelmax jig I made to drill intoi faces of 45 degree joints -small.JPG 
Views:	36 
Size:	74.8 KB 
ID:	41503 Click image for larger version. 

Name:	Music box 01 -One of the mitre joints -small.JPG 
Views:	33 
Size:	88.5 KB 
ID:	41504

    Next, I sanded and polished the interior sides of the box pieces up to 4000 grit: Click image for larger version. 

Name:	Music box 02 -The interior sides of the box pieces were sanded and polished up to 4000 -small.JPG 
Views:	34 
Size:	109.4 KB 
ID:	41505

    The next step was to route an indent in the front side exterior for the lid latch to fit into when shut: Click image for larger version. 

Name:	Music box 03 -Starting to route an indent in the front exterior for the lid latch -small.JPG 
Views:	33 
Size:	95.1 KB 
ID:	41506

    I used the template in the foreground to set the stop locks on the router table. The reason for all this is that the notch only goes part way through the front side.

    Now it was time to glue-up the basic box: Click image for larger version. 

Name:	Music box 04 - Box glue-up -small.JPG 
Views:	35 
Size:	102.3 KB 
ID:	41507
    Cheers, Frank

  2. #2
    Join Date
    Oct 2006
    Location
    Toronto, Ontario, CANADA
    Posts
    2,332
    (part 2 of 4)

    2009, Dec 20:

    I continued work on the music/jewellery box. First, I made a jig to cut slots for two splines across each corner of the box. The plans called for splines 1/8 inch in thickness, but I decided to make them 1/4 inch.
    Click image for larger version. 

Name:	Music box 05 -Cutting slots for decorative splines with a home-made jig -small.JPG 
Views:	30 
Size:	97.5 KB 
ID:	41509 Click image for larger version. 

Name:	Music box 06 -Gluing in decorative splines -small.JPG 
Views:	28 
Size:	88.2 KB 
ID:	41510 Click image for larger version. 

Name:	Music box 07 -Decorative splines trimmed and rough sanded -small.JPG 
Views:	24 
Size:	93.1 KB 
ID:	41511

    I did not bother to sand the sides any further than 8 grit, because they were about to be beveled at 6 degrees. Before doing this, I cut 4 small feet out of a slice of walnut. This time I used my small bandsaw: Click image for larger version. 

Name:	Music box 08 -Trimming the feet aon small bandsaw -small.JPG 
Views:	23 
Size:	77.2 KB 
ID:	41512

    Now it was time to cut the bevels:
    Click image for larger version. 

Name:	Music box 09 -Bevelling three of the sides -1 -small.JPG 
Views:	34 
Size:	102.4 KB 
ID:	41513 Click image for larger version. 

Name:	Music box 10 -Bevelling three of the sides -2 -small.JPG 
Views:	39 
Size:	86.2 KB 
ID:	41514 Click image for larger version. 

Name:	Music box 11 -Bevelling three of the sides -3 -small.JPG 
Views:	36 
Size:	94.0 KB 
ID:	41515 Click image for larger version. 

Name:	Music box 12 -The dowels are now visible -small.JPG 
Views:	33 
Size:	74.8 KB 
ID:	41516

    I screwed up! The dowels that I had inserted on the faces of the 45 degree joints to assist positioning during the glue-up were now revealed. What to do?

    I drilled some larger holes, made a few short dowels out of some walnut, glued them into the holes, and sanded and polished all the sides up to 4000 grit.
    Click image for larger version. 

Name:	Music box 13 -Dowles used for corner joints now hidden by walnut dowels and box has been polishe.JPG 
Views:	67 
Size:	113.5 KB 
ID:	41517

    It creates a strange pattern on the two front corners which I don't like but which Margaret says she likes. I might give the box looking like this to Isla or I might try to make another. Her birthday is not until January 18, so I put the box aside for a while and I will make the decision early in the new year.
    Last edited by Frank Pellow; 01-18-2010 at 05:49 PM.
    Cheers, Frank

  3. #3
    Join Date
    Oct 2006
    Location
    Toronto, Ontario, CANADA
    Posts
    2,332
    (part 3 of 4)

    2010, Jan 17:

    Since Isla's birthday is tomorrow, I got back to her jewellery/music box this week. When I last reported about this project on December, I had just compensated for a big mistake and was contemplating starting a brand new box for Isla. Well, I never got around to it, so the box she is getting is the one with the mistakes.

    The next step was to attach a lid. This entailed cutting notches for some fancy box lid stop hinges (part number 01B03.02 at Lee Valley). The magazine plans showed a technique for cutting the notches with a router but, with my routing skills, that seemed somewhat risky. So, I opted for the tried a true method for makes hinge notches with saws, chisels, and wood files:
    Click image for larger version. 

Name:	Music box 15 -Sawing sides of notches for hinges -small.JPG 
Views:	21 
Size:	92.1 KB 
ID:	41518 Click image for larger version. 

Name:	Music box 16 -Chisels and file used to cut hinge notches -small.JPG 
Views:	20 
Size:	93.6 KB 
ID:	41519

    I did a good job on the notches, but not such a good job screwing in the hinges. They screws supplied with the hinges were quite week and, although I had drilled a small pilot hole, one of them broke off:
    Click image for larger version. 

Name:	Music box 17 -Broken screw -small.JPG 
Views:	23 
Size:	75.9 KB 
ID:	41520

    This breakage resulted from two different factors. First of all, the #3 brass screws that came with the hinges seem to be very weak. Secondly, although I predrilled a hole for the screw, there was still pressure on it to cut the threads in the hard Cherry wood.

    I went back to Lee Valley and purchased some #4 brass screws that appear to be of better quality than the screws that came with the hinges. The screws that came with the hinges were to long for the lid anyway, so I would have needed some different screws anyway. I selected 3/4 inch screws to use in the box and 3/8 inch screws to use in the lid. Then, I drilled out the broken screw and glued a piece of very narrow maple dowel into the hole:
    Click image for larger version. 

Name:	Music box 18 -Drill out the screw -small.JPG 
Views:	21 
Size:	64.1 KB 
ID:	41521 Click image for larger version. 

Name:	Music box 19 -Plug the hole with a dowel -small.JPG 
Views:	22 
Size:	91.2 KB 
ID:	41522

    Before using the new brass screws in the hinges, I first screwed in then screwed out a #4 steel screw: Click image for larger version. 

Name:	Music box 21 -Hinges installed on the box -small.JPG 
Views:	22 
Size:	97.9 KB 
ID:	41523

    Before drilling holes in the box for the music mechanism, I made a small template out of thick paper:
    Click image for larger version. 

Name:	Music box 22 -Making a template for the music mechanism -small.JPG 
Views:	23 
Size:	118.7 KB 
ID:	41524 Click image for larger version. 

Name:	Music box 23 -Positioning the template to use as a drill hole guide -small.JPG 
Views:	18 
Size:	67.6 KB 
ID:	41525

    A small box within a box was made to protect the music mechanism. The box was made of 3/8 inch Cherry with a Plexiglas top. A small notch was cut in the side of the box to accommodate the wire used to start and stop the flywheel that, in turn, starts and stops the cylinder used to make the music. I marvel over the Swiss-made mechanism.
    Click image for larger version. 

Name:	Music box 24 -Glueing together the walls of the box within a bos to be used to encase the music .JPG 
Views:	19 
Size:	92.9 KB 
ID:	41526 Click image for larger version. 

Name:	Music box 25 -sub-box walls have been glued into place and plexiglass lid has been cut -small.JPG 
Views:	23 
Size:	108.2 KB 
ID:	41527

    Finally, the box was waxed with Talk Orange Wax which is a combination of beeswax carnauba wax and orange oil.
    Last edited by Frank Pellow; 01-18-2010 at 06:05 PM.
    Cheers, Frank

  4. #4
    Join Date
    Oct 2006
    Location
    Toronto, Ontario, CANADA
    Posts
    2,332
    (part 4 of 4)

    Below are a few photos of the finished box.

    Interior: Click image for larger version. 

Name:	Music box 26 -Finished interior -small.JPG 
Views:	37 
Size:	89.1 KB 
ID:	41528

    Front: Click image for larger version. 

Name:	Music box 27 -Finished front -small.JPG 
Views:	47 
Size:	104.9 KB 
ID:	41529

    Back: Click image for larger version. 

Name:	Music box 28 -Finished back -small.JPG 
Views:	42 
Size:	119.1 KB 
ID:	41530

    Side: Click image for larger version. 

Name:	Music box 29 -Finished side -small.JPG 
Views:	44 
Size:	87.4 KB 
ID:	41531

    Bottom: Click image for larger version. 

Name:	Music box 30 -Finished bottom -small.JPG 
Views:	68 
Size:	122.0 KB 
ID:	41532

    (I have got to get better at this branding business )
    Last edited by Frank Pellow; 01-18-2010 at 06:08 PM.
    Cheers, Frank

  5. #5
    Join Date
    Oct 2006
    Location
    somewhere east of Queen Creek, AZ - South East of Phoenix
    Posts
    8,529
    "There’s a lot of work being done today that doesn’t have any soul in it. The technique may be the utmost perfection, yet it is lifeless. It doesn’t have a soul. I hope my furniture has a soul to it." - Sam Maloof
    The Pessimist complains about the wind; The Optimist expects it to change;The Realist adjusts the sails.~ William Arthur Ward

  6. #6
    Join Date
    Mar 2008
    Location
    new york city burbs
    Posts
    10,184
    very, very pretty, she is gonna love it.

  7. #7
    Join Date
    Jun 2008
    Location
    GTA Ontario Canada
    Posts
    12,243
    Great project Frank nice post too. I dont see anything wrong with your branding. Looked pretty clear to me.
    cheers

  8. #8
    Join Date
    Mar 2007
    Location
    Escondido, CA
    Posts
    5,167
    Very Nice!

  9. #9
    Join Date
    Jan 2007
    Posts
    810
    .,.,.,
    Last edited by John Bartley; 12-02-2010 at 02:30 AM.

  10. #10
    Join Date
    Oct 2006
    Location
    ABQ NM
    Posts
    30,002
    Great job Frank, and a couple of nice recoveries in there as well.
    When the going gets weird, the weird turn pro. - Hunter S. Thompson
    When the weird get going, they start their own forum. - Vaughn McMillan

    workingwoods.com

Similar Threads

  1. Brother Rod and Wife Cherry made it to Md
    By Dave Hawksford in forum Off Topic Discussion
    Replies: 0
    Last Post: 09-02-2013, 01:31 PM
  2. WTB walnut, cherry and maple
    By John Moore in forum Classified Ads
    Replies: 3
    Last Post: 05-20-2012, 08:11 PM
  3. Wood choice made - what do you know about Brazillian Cherry?
    By Rennie Heuer in forum General Woodworking Q&A
    Replies: 28
    Last Post: 04-28-2012, 09:09 AM
  4. Air dried walnut and cherry question
    By John Daugherty in forum General Woodworking Q&A
    Replies: 11
    Last Post: 11-24-2008, 02:59 PM
  5. Walnut & Cherry
    By Rob Bodenschatz in forum General Woodworking Q&A
    Replies: 17
    Last Post: 02-14-2007, 02:39 PM

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •