bookmark_borderPine Boxes with Rabbet Joinery

A “rabbet” or “rebate” is a slot cut right at the edge of a piece of wood, as opposed to a “dado” which is a slot cut somewhere in the middle. Last Spring, when I was trying to get the BMDL woodworking guild going, one of the workshops I put together was about how to make these simple wooden boxes. The rabbet joinery is much stronger than butt joinery. Glue along two axes is stronger than glue along one, the rabbet around the bottom keep the whole thing square if you do it right, and the rabbet around the lid lets the lid fit snugly. I wound up making three boxes myself. Two were prototypes to test my process, and one was the “follow along” version made during the workshop. These sat around for about a year, but then I decided to practice finishing with shellac. I declared them “done” just recently.

Three pine boxes with rabbet joinery

I used some ancient Zinser-brand amber shalleac on two of them, in a futile attempt to get rid of the last of that stuff. On the third, I used a blonde shellac that I mixed myself from flake shellac and denatured alcohol. Some people don’t like the the color of the amber shellac. I think it’s OK. The blonde shellac looks a lot more natural,though. Here they are with the lids off:

The thickness of the walls i kind of overkill for a box this size, but planing the wood down just wastes it. If things ever get back to near normal, I should run a finishing workshop. A lot of people hate finishing, because nobody ever taught them how to do it well. I’ve learned so much through trial and error that I don’t mind it, even though it takes up a lot of time and delays the completion of projects.

bookmark_borderCherry Surplus Box Project

Just in case you are under the impression that everything I do is always perfect, here’s a little project I had to make because I messed up my first try on the Sake Cup Box project. Sometimes I kind of “wing it” on projects, making decisions based on dimensions that are are penciled on cardboard boxes or post-it notes instead of sitting down to draw up formal plans and doing calculations. As you might expect, sometimes this bites me in the butt.

I made this box bottom, then when I tried it out with the dividers to check for size, I realized it was too small. I set it aside while I started over on a new box bottom, kept it aside while I made a lid for the Sake Cup Box, then I made a lid to fit this “surplus” box bottom instead of smashing it to bits in frustration.

Surplus Box Bottom

This time, the top of the lid is made from more strips of cherry, edge-glued together. I am getting tired of seeing this big stack of cherry scants in the shop, so this was a good way to use up a handful of them. The walls are also cherry strips, but I was able to get better glue joints this time, so there is no metal hardware. Hopefully, the whole thing doesn’t wind up smashed to pieces at some point.

Cherry Surplus Box

The floor is maple, resawn and bookmatched, but as this was my first try it is much more uneven than the floor of the Sake Cup Box. In a way, it’s a good thing this one was unusably small because the bottom it’s definitely not as nice.

The whole thing got the same walnut oil finish as the Sake Cup Box, because why not, so it also spent the last month in the drying closet. I’m no entirely sure what I’ll use this box for, but I am sure that I will use it for something. It’s big enough to hold 16 tama and some braiding supplies, and since it obviously matches the Cherry Marudai, maybe that’s what I will use it for.

bookmark_borderSake Cup Box Project

It spent a month in the furo, and now it’s ready to show off. This was one of my big projects last month, and it has been on my to-do list for a while.

Back at the SCA 50-year anniversary event, we purchased a dozen sake cups for a very good price from a merchant. Since a dozen is one box of cups, the merchant threw in the box so we could safely transport the cups home. This was just a cardboard box, so we have been keeping the cups in a plastic bento box ever since. The cardboard dividers between the cups got destroyed at Pennsic last year, so I made some new dividers from cherry, but still sized to fit in the plastic bento. Now, I have made the final box.

The Sake Cup Box

The top of the lid is made from some rough-sawn lumber I salvaged from Mr. Arimoto’s workshop during the restaurant furniture project. The walls of both the lid and the box body are made from off-cut cherry strips from making maurdai. I was having some trouble gluing the strips to the lid and floor pieces, so all the joinery is secured with brass escutcheon pins. This should also make it a little more durable. It’s finished with food-grade walnut oil, which is why it had to spend a month in the drying cabinet. That oil takes a really long time to cure.

Here’s what it looks like with the lid off:

Sake Cups in Box, with Dividers

The dividers are neither glued together, nor are they glued in. If I need this box for something else later, they will lift right out. The floor of the box is some resawn and book-matched maple that I had in the shop. I didn’t have enough or thick enough cherry left over. It started as 4/4 (roughly 1-inch thick) maple, so I resawed it to roughly half-inch thickness, then sanded it smooth and even.

Empty Sake Cup Box

I am really super-happy with the way this came out. It is significantly larger and heavier than the old plastic box, but it is also significantly classier.

bookmark_borderIn the Furo

A furo is a “drying cabinet”. It’s where you put urushi lacquered objects to keep them warm and humidified until the lacquer has fully cured. Depending on the type of lacquer, this could take a number of weeks. In my case “furo” is actually short for “furnace room”, which is a nice warm room in the house that also contains the hot water heater.

I’ve been working on a couple of wooden box projects, and I decided to finish them with walnut oil. Walnut oil is a drying oil (like boiled linseed oil), but it contains no chemical drying agents like BLO does and is food safe. The down side is that it takes about a month to cure, so I can’t show these boxes as finished projects for some time.

Boxes in the furo

Both boxes are constructed primarily of 1/4″ cherry scants. These are off-cuts from trimming down the legs of the two cherry marudai I made. The floors of both boxes are bookmatched resawn maple. The floor of the smaller box is the result of trying to make the larger box and having it come out a little small due to lack of planning. The lid of the smaller box is more 1/4″ cherry that has been edge-glued into a single panel. The lid of the larger box is 3/4″ rough-sawn cherry salvaged from the scrap pile at Mr. Arimoto’s shop. Once the oil went on the raw surface of the cherry, the whole thing went deep and beautiful.

I’m going to try to resist the urge to peek in on them constantly. We’ll see how they look in a month.