Woodworking

Ideas:
SPRING BOX
83

ROUND-DRAWER

How to Unlock the Imagination

The round-drawer spring box is a puzzle box on top of a spring-loaded drawer. Youll
be challenged to create a layered box that will give you further insight into the world

of puzzle boxes. As you can see here, spalted maple makes an attractive box. Enjoy!

Includes bonus
puzzle box plan
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Sketching: Its All in Your Mind

Try this exercise to unlock imagination.

n the rst century B.C.E., a military

architect named Vitruvius captured
the distinction between a designers
mind and the minds of the rest of us.
For all men, not just architects, are
capable of appreciating quality; but
there is a difference between laymen

and architects (designers) in that the

former cannot know what a building will
be like unless he has seen it completed;
while the architect knows perfectly well
what it will be like from the instant
he conceives it in his mind, and before
he begins it.

Vitruvius nailed it especially the

part about not being able to visualize.
For years I struggled with this. In fact,
its embarrassing to admit, but even a
good photo or shop drawing couldnt cut
through my fog. Often, Id nd myself
surprised at the completion of a project.
The image in my head and the object were
never one and the same, as though I had
a mild case of visual amnesia.
Considering that I started from zero,
I speak from experience when I say that
the ability to visualize is a developed
skill. Its not unlike learning to sharpen a
plane iron. All it requires is a bit of practice and a willingness to push aside your
self doubt. At its simplest, the ability to
visualize consists of drawing pictures in
your mind. To start that process heres
a simple sketching exercise to enhance
your ability to imagine forms.

A Different Take on Drawing

This method of sketching is different from mechanical drafting (which
seeks a technically precise image), and
its not creative doodling in search of
an inspiring idea. Instead, the purpose
is to awaken your ability to imagine by
encouraging your mind to unpack an
object in space. Your actual sketch may
look crude on paper, but if the idea transfers clearly in your head, thats all that
matters. Dont shortchange yourself by
just reading this to get the concept. Pick
up a pencil and take your hand and eye
through the steps in this dance to rewire
the circuits in your head.

Application

Beyond drafting. Theres more to drawing than drafting. Simple sketching cleans the bugs off the windshield in your head.

POPULAR WOODWORKING MAGAZINE

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February 2012

You need a sketchpad, pencil, straightedge and a pair of dividers. Resist the
temptation to use graph paper or a ruler
with markings on it; the numbers and
lines will only fog your thinking. Forget
about measurements or grids for now.
PHOTOS BY THE AUTHOR

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DESIGN MATTERS
Tools for
imagination.
Dont let the
simplicity fool you
this is a powerful
tool kit to rev up
your imagination.

Eyeball proportions. Practice sketching a

small object, such as this childs chair. With arm
extended you can pluck the proportions using
the end of the straightedge and your thumb.

We are focusing on uncovering a form

and probing how its organized visually. Select a small object to draw. The
toddlers chair above is simple, but with
enough detail to give the mind something
to explore spatially. Also, this works better with a pencil than with a mouse. Your
senses are a portal into your imagination
and you want a clean connection between
ngertip, eye and brain.

Lets Get Started

First lets capture the essence of the form
that governs this chair. A form is nothing more than a few simple shapes that
combine to dene an object in space.
We begin by roughing in the simplest shape the eye can detect, in this
case a rectangle that governs the overall
width and height of the object. Hold your
straightedge at arms length and span the
widest part using your thumb to mark
the width. Use that to draw the bottom of
your rectangle and grab the height using
the same method to create the sides. Connect all four sides then stop a moment
to look at what youve rendered. Youve
just sketched a proportionally correct
shape that governs the space that your
eye perceives.
POPULAR WOODWORKING MAGAZINE

18-21_1202_PWM_DesignMatters.ind20 20

Simplicity rst. Transfer what you see to a sketch

on paper, starting with a simple rectangle.

Now turn to the next level of detail:

roughing in the smaller shapes that organize the form. Use your straightedge and
thumb to grab the height of the seat and
the width of the chair back. The overall
form is now subdivided into major parts.
Often these larger blocks will use proportions to create a hierarchy between
major and minor; but for now, just focus
on being able to see the largest shapes
and how they are arranged.
Starting from large shapes, move
down to small details; sketch every element using your thumb and straightedge
to render the parts in proportion to the
whole. You may also nd it helpful to
use dividers to pluck the smaller details.
Work that pencil and simultaneously
feed the part of your brain that paints
objects in space. Think of it as teaching
yourself guitar chords visually rather
than aurally. Over the next few weeks,
pick a variety of interesting objects to
sketch and unpack. This is just scratching the surface of what you can do but
its surprising how quickly your imagination will respond. In just a short time,
youll forget where you left that mild
case of visual amnesia. PWM
George is the author of two design DVDs
from Lie-Nielsen Toolworks (lie-nielsen.com).

Minor additions. Small additions lead to a

major leap youve captured the form.

Add the details. Your sketch may surprise you on

paper, and most importantly in your minds eye.

ONLINE EXTRAS
For links to all these online extras, go to:
popularwoodworking.com/feb12
BLOG: Read more from George about design
on his Design Matters blog.
IN OUR STORE: George R. Walkers design DVDs.

Our products are available online at:

ShopWoodworking.com

About This Column

Design Matters dives into the
basics of proportions, forms,
contrast and composition to
give you the skill to tackle furniture design
challenges with condence.

February 2012

11/30/11 4:56:44 PM

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83

ROUND-DRAWER

SPRING BOX
The round-drawer spring box is a puzzle box on top of a spring-loaded drawer. Youll
be challenged to create a layered box that will give you further insight into the world
of puzzle boxes. As you can see here, spalted maple makes an attractive box. Enjoy!

Z2116i_pg082-095.indd 83

10/20/09 4:55:45 PM

84

S E CT I O N T W O

2
STEPS 1-4 On the side of the 4x4, 6"-long box
blank, draw three horizontal lines. The first line is
approximately 1 4" from the bottom of the blank.
Draw the second line about 1" from the bottom of
the blank and the third about 1 4" above the second
line. Draw a fourth line down that intersects these
three lines. This line will help you orient the parts
at assembly time. Cut the three horizontal lines as
straight as possible.

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Cut a dovetail key from one corner of the thick top

piece. Then cut a lid from the top piece that runs
the length of the box and has a sliding dovetail
about 2 3 in from the end you have chosen as the
back. Enter through the dovetail key and cut out
the guts.

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RO U N D- DRAWER S P RING B OX

6
STEPS 5-6 Cut out a corner from the guts.
This compartment conceals a key that locks and
unlocks the sprint-loaded drawer. To make this
key, cut out the framework wall as you would for a
small inner box. Pull the block of wood from inside
the framework.

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STEPS 7-8 Cut off the top of the piece to make a small
lid. Turn the leftover piece on its side. Begin at the center
and mark off 1 8" on either side of the center point. Cut
inward from these points until you reach approximately
3 16" from the bottom. Back the blade out and make a
parallel cut 1 8" in from each end. Now cut out the wood
on either side of the center between each of those sets of
parallel cuts. Study the photos to help you visualize the
cuts. Set these pieces aside for the moment.

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S E CT I O N T W O

10
STEPS 9-11 Turn your attention back to the
bottom 1"-thick piece of wood. Identify the side
where the key and the little compartment from the
upper section will be located. Using a compass,
draw a semi circle as large as the wood will allow.
Draw it so the drawer will exit beneath the small
divided compartment above it. Then draw a
concentric semi circle that is about 3 4" in diameter.
Where the drawer comes out of the wood, make a
flare that creates a lip (see step 11).

12

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11
STEPS 12-13 Up until now weve been using an
1 8" .025" 14T blade. To cut an inner drawer like this
one, you need to use an 1 8" .020" 14T blade. This
thinner blade will not make turns that are as tight as the
thicker blade, but the kerf is smaller, allowing the drawer
to fit better. Cut out the drawer. The arm shown in step
13 (see arrow) is a drawer stop and the bulge on the
end of the arm is the pivot for the drawer.

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RO U N D- DRAWER S P RING B OX

14
STEPS 14-15 Make the drawer bottom about
1 8" thick.
STEP 16 Cut a small sliver from the back of the
drawer that tapers from an 1 8" to 0", with the thicker
part beginning at the outer semi circle and the thinner
part at the inner semi circle. This allows relief for
the drawer to fit snugly into the box, concealing the
drawer so it is not easily seen.

16

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15
STEP 17 With the bottom held back in place on the
drawer, the missing sliver is shown more easily. The
extended bottom is a drawer guide that can be carefully
sanded to provide a perfect fit of the drawer in the box.

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S E CT I O N T W O

18

19
STEPS 18-20 Cut out the inside of the drawer,
starting at the back of the drawer and, leaving the
back about 1 2" thick, tapering down to follow the
small inner curve and tapering again to leave the
wood 1 2" thick at the outer face of the drawer,
continuing around the rest of the curve at 1 8" thick.
Remember to leave a tapered lip at the end of this
cut so that you have something to clamp onto
when gluing. Back the blade out carefully. Remove
the center of the drawer and cut a handle into the
top. Cut this top off to make the lift-out lid.

21

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20
STEPS 21-22 Cut the two shoulders for the drawer to
hold up the lift-out lid.

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RO U N D- DRAWER S P RING B OX

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24

STEPS 23-24 Remove the burrs and glue the

bottom onto the box. Add weights.
STEPS 25-26 Before gluing the bottom onto the
drawer section, sand the outer radii of the semi circle
where the drawer will insert into the box. Remove just
the saw marks to reduce friction, letting the drawer
slide in and out smoothly. Now glue the bottom
onto the drawer section, again wiping to avoid glue
squeeze out inside the box.

25

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S E CT I O N T W O

27
STEPS 27-28 Fit the bottom on the box, and
add spring clamps to hold the bottom in place.

29

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28
STEPS 29-30 When the glue has set up, sand the top
of the bottom section and the bottom of the top section
of the box until the saw lines are gone (see arrows in
step 29). Apply glue, position them together, line them up
perfectly and add weights. Make sure no glue squeezes
out into the cavity that the drawer will slide into. It will be
very difficult to remove any glue squeeze out once the
box is assembled.

30

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RO U N D- DRAWER S P RING B OX

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32

STEPS 31-32 Glue the drawer seam, again adding

spring clamps to hold the joint closed.
STEPS 33-34 Glue the bottom on the drawer. Then,
double check the placement of the shoulders in the
drawer by inserting the lid into the drawer, making
sure it seats properly. Glue the shoulders in place.

33

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S E CT I O N T W O

35
STEPS 35-36 Hold the shoulders in place using
clothes pins.
STEP 37 Inside the top section of the box, glue
the framework for the drawer-release key and the
shoulders in place.

37

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36
STEPS 38-39 Sand the box seams using a stationary
belt sander. Sand the rounded edges (that Im pointing
to with my fingers) of the drawer using a spindle sander.
Fit the drawer to its opening in the box. If needed,
sand lightly on the bottom of the drawer so it will slide
smoothly into the box. Dont change the contour of the
drawer bottom where it meets the outside of the box. You
want the drawer to be as invisible as possible.

38

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RO U N D- DRAWER S P RING B OX

39

93

40

STEPS 40-42 In the back of the drawer, where the

wood was left thick, drill a 1 2" hole about 3 8" deep for
the spring. (You can find the spring [mine is a #186] or
a similar one at your local hardware store.) Temporarily
insert the spring into the hole.

41

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S E CT I O N T W O

44

43

45

STEPS 43-45 Back to the divider key cut in Step 8.

Cut a thin sliver off the top of the middle, vertical leg
of the divider. This sliver is thin, but save it.
STEPS 46-48 Insert the divider key into its
framework. Insert the drawer (with the spring) into the
box. While holding the drawer closed as tightly as
possible (photo 47), drill a 1 8" hole through the divider,
the bottom of the upper section and into the drawer in
the bottom section. Dont drill through the bottom of
the drawer!

46

47

48

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RO U N D- DRAWER S P RING B OX

49
STEPS 49-51 Cut a 1 8" dowel about 1" long and
sand one end to a point. Put glue into the hole and
on the top of the center finger of the divider. Insert
the flat end of the dowel into the hole from the
bottom of the divider, add the sliver of wood from
Step 43 and clamp it in place.

51

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50
STEP 52 With the spring in the drawer, insert the
drawer into the box and push the pin and divider into
place, which will lock the drawer in place. The drawer
front will probably be recessed a little from the face of
the box. Sand the boxs face until it is flush with the
drawers face. Put the lid on the box and sand the box
until all the parts are flush. Do any touchup sanding
and finish the box. Then, glue the coil spring into place
using a little dab of hot glue.

52

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