To make a wooden box sounds like a simple proposition; but in making
the drawing, the questions of size, proportion, joints, hinges, etc.,
immediately come up.
The size of course depends on the purpose of the box. If it is for
ladies' gloves, it should be long and narrow; if for collars or
handkerchiefs, square or nearly so. The height is nearly always made
too great. In fact, the whole question of proportion is one which can
hardly be taught; it must be felt, and different people have different
ideas as to what constitutes good proportion.
Some hints, however, may be given: A box perfectly square does not look
well. Again, dimensions that are multiples do not look well. A box 4
× 8 × 12 inches would not be nearly so pleasing as one 3 × 5-1/2 × 12
inches.
The proportions are also affected by the constructive details. Is the
box to be flat on the sides and ends or is the top to project? etc.
Our boys argued and sketched and finally drew the design shown at Fig.
148. This was to hold ties. The top was to project and have a bevel, or
chamfer, also the bottom. No hinges were to be used, but the cover was
to have cleats fastened on the under side to keep it in place, and to
prevent warping.
[Illustration: Fig. 148. Dado joint used in box design]
The next question was the manner of fastening the sides and ends. On
unimportant work, a butt joint with glue and brads can be used, but for
a toilet article, the holes made by the brads, even if they are filled
with putty, are not satisfactory.
So it was decided to use the dado joint as shown at _a_. This meant
more fine work, but, as Ralph suggested, it was to last a lifetime, and
should be made right.
Sides and ends were squared up, and the grooves on the side pieces laid
out as in the nail box. The rabbets on the end pieces were cut out with
the back saw and chisel. After the joints had been carefully fitted,
the four pieces were glued together and placed in hand screws over
night.
While the glue was hardening, the two pieces for the top and bottom
were squared up and bevelled with the smoothing plane on the long
sides, the block plane on the ends.
The cleats for the top were next made, drilled and countersunk for the
screws as at _b_.
A careful full-sized drawing of half of the top was made, and a chip
carving design drawn for it. The cleats were not put on until the
carving was finished and short screws had to be used so they would not
come through and spoil the surface.
The next day the body of the box was removed from the hand screws
and squared with a smoothing plane. The top and bottom were put on
with 1-inch brads. These were "set" with a nail punch to prevent
any possible scratching and the whole box was rubbed down with wax
dissolved in turpentine.
For fine cabinet work, the dovetail joint makes the most satisfactory
method of fastening, but Harry was not yet skilled enough to do the
fine work it demanded.
The second box was for handkerchiefs, dimensions 8 × 7 × 3 inches
outside, and no overhang at either top or bottom. The construction
brought in several new features. Sides and ends were dadoed together as
in the first box.
The top and bottom, after being squared, were rabbeted on all four
sides until they fitted snugly into the opening top and bottom. They
were glued in these positions and placed in hand screws over night.
(Fig. 149.)
"How are you going to get into that box?" asked Harry. "You've closed
it up solid and glued the top on."
"Wait and see," was all the satisfaction he got.
[Illustration: Fig. 149. The handkerchief box]
The next day the hand screws were removed and the box squared up
exactly as if it had been a solid piece of wood. Ralph then made two
gauge lines around the four sides, 3/4 inch from the top and 1/8 inch
apart. Then he cut the box in two between these two lines with a rip
saw, after slightly rounding all corners except the bottom ones with a
plane and sand-paper.
By this method, the box and cover must be exactly alike in outline, and
by planing to the gauge lines, they will fit perfectly.
It only remained to hinge the two parts together, but this operation
proved to be no slight task.
The body was placed in the vise and the cover laid upside down on the
bench top. The two parts were brought together as shown at _c_, and the
four knife lines laid out as shown with knife and try square.
The distance between the lines at _a_ and _b_ must be equal to the
width of the hinge, and the wood between these lines removed to a depth
equal to half the thickness of the hinge at its joint when closed. If
too much is removed, the box will be "hinge bound" and will not close
in front. If too little is taken out, it will close in front and have
an open joint at the back. In the former case, a thickness or two of
paper placed under the hinge will often be enough to make it close in
front. In the latter case, of course more material must be cut out. It
is a delicate operation, as the depth of these cuts for 1-inch hinges
is only about 1/16 inch. It is a question of accuracy, pure and simple.
Holes for the screws can be made with a brad awl.
The boys made several boxes of various sizes and styles, some plain,
some decorated with carving. Pyrography, or burnt work, is frequently
used for decoration, and the best wood for this purpose is basswood,
because of its white color, softness, and freedom from pitch.
Other woods may be burnt, but pine, which has veins of pitchy sap, is
not suitable.
[Illustration: Fig. 150. A box for drawing instruments]
A box for drawing instruments is shown in Fig. 150. Its outside
dimensions are 9 × 5-1/4 × 2-1/2 inches. Our boys made theirs of gum
wood because of the beauty of its colouring and its suitability for
carving. The joints used and the method of construction were the same
as in the handkerchief box, but it was provided with a tray for the
instruments. This was one inch deep over all, and rested on two thin
strips fastened to the ends inside. These strips were 4-1/4 × 1 × 1/4
inches, and, by raising the tray one inch from the bottom, left a space
convenient for holding triangles, protractors, pencils, etc. The cover
was decorated with a border and centre piece in chip carving.
The making of dovetailed boxes is taken up in Chapter XXXV.