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    Creating Wooden Boxes On The Scroll Saw - Patterns and Instructions For Jewelry, Music, and Other Keepsake Boxes

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    td SCROLLSAW “ caERTTE WOODEN BOXES onthe Scroll Saw 16 20096) Fox Chase Publehing Compt: ne. ‘Geoting Wooden Bones the Se Saw san crginal wok fst pubshed in 2008 by Fox Chapel Rublshing Company, ne The pats camaned here ie copyrighted by the author Rese smaymoke copies of thove pater for pesonal use. The patterns themsalrs, hone ae nt bbe dupicateor resale ordstcbuton undet ary ckcustances. ny such copying savalation of consnight an HON oe sonasetS Lutrary of Congress Catslegng in Fubleaon Dats ‘cresting wooden boxes on the scroll sa by the ecto of Sc ett, f.cm.— (The best of Scot sau woodworking fers magazine) Includes index lane 978 1565234444 1 Woodwork 2. Wooden boxes 3 saw wootwarting & 21s. | Scrolls ncodwarking ras T2004 2009 cotnd-e22 2000019667 Talearmore shoutthe ether reat becks fren Fon Chapel Publehing ot tend atetler near ou, cal ol ee 800-487-811 or vst us at nw FoxchapePuttshing om, Note to Author: N= eave ooking fr tale authors tow te ew books inoue aes of mocdnceing. design and rated cats las seta bie eter escribir your eo t Acquistion tor, 1970 Sead Suee, Est Petersburg PA 17520 incedin ching Fratpntrg August 2009 Table of Contents z , z Ter i x ed 3 . eS s i inf ae r Nesting Basket THO ensue. eatmneer TT ia . : e ) 7 ; i 5 ee 5. ‘ \ Slope-Sided 8 ee ‘ What You Can Make Functional Boxes Potpourri Box. Holiday Card Halder Page 19 Page 43 Texas Hold-'Em Caddie: Page 74 Nesting Basket Tio Page 77 Maple Leaf Jewelry Box Patriotic Flag Box Page 83 Page 94 Fantasy Boxes Swan Lake Keepsake Box Fantasy Keepsake Boxes Page 4 Page 54 Mirrored Flower Box with Copper and Patina Page 114 fantasy Keepsake Boxes Page 54 ‘Magazine Storage Case Page 118 i | ! Dragon Chest Page 63 Keepsake and Jewelry Boxes Walnut and Brass Keepsake —_PetakPerfect Rose Box Eagle Keepsake Box Hanging Backpack Box Box Page 38 Page 48 Page 52 Fage60 Four-in-One Boxes Slope-Sided Box Ribbons and Bows Box Page ss Page 110 Page 121 Antique-Inspired Boxes e=2 Gentleman's Box Renaissance Keepsake Box Victorian FretworkMusic Box Good Luck Box Page 22 Page 26 Page 30 Page 35 Puzzle Boxes ‘Siding Panel Puzzle Box Secret Chamber Puzzel Box Page 100 Page 106, Introduction Scroll Saw Woodworking & Crafts magazine presents a collection of the best box patterns for scroll sawers. On the following pages, you'l find pattems, tips, techniques, and stories from many of our contributors, hopefully along with inspiration to try the boxes shawn in the book and your own variations and new creations. ‘The boxes contained here are broken down into categories— Fretwork Boxes, Segmentation and Intarsia Boxes, Layered Boxes, and One-of-a- Kind Boxes—to help you find just what you're looking for, Hanging Backpack 60x, bby Sue Chrestensen, page 60 8 Creating Wooden Baves onthe Scroll Saw = Introduction Scroll Sawing Basics If youre new to scrolling, read through the following, information before you actually begin at your saw. Safety. Though the scroll saw isa relatively safe tool, take the time to make sure you're working safely. Check that your work area is clean, well lit, well ventilated, and uncluttered. A dust collector, mask, air cleaner, or a combination af these items can help protect your lungs fom fine dust. Wear some type of safety goggles just in case a piece of wood should break free and fly toward your face and eyes. Remove any loose clothing ‘or jewelry before you operate the saw. Don't work while you are tired, and, of course, keep your hands and Fingers a safe distance away from the blade. ‘Tools. Gather your tools before you begin so everything is close at hand. The projects here list the general tools you'll need and often give other suggestions and options. Remember, the lists are simply guidelines and you should always work with tools you fecl comfortable using, Squaring the blade. Before you begin any cutting, always check that your blade is square, or 90° to the: scroll saw table. This will ensure your cuts are accurate. You can use any type of squate to cheek the angle of the blade to the table. IF you don’t have a square, try the 10 Creating Wooten Boxes onthe Scroll Saw + Introduction kerf-test method usinga piece of serap wood. First, make a small cut, about J long, in piece of scrap ‘wood abaut 14” thick. Stop the saw. Then, turn the scrap wood around until the cut is facing the back of, the blade. Slide the wood actoss the table so that the blade fits into the cut. Ifthe blade slips easily into the Cut, it issquare, If the blade daes not stip eastly into the cut, adjust the table and perform the test again until the blade slips in easily and is square. Stack cutting. This technique of simply adhering together and cutting more than one piece of wood at the same time can save you time and effort. It can also ensure better fit for identical pieces. Pieces of wood can be held together with double-sided tape, painter's or masking tape around the edges, or nails tacked into the waste areas of the wood. If you use nails, be careful that the ends of the nails do not poke through too much and serateh your saw table. Ifthey do poke through, you can use a hammer or sandpaper to make them flush with the bottom of the stack Familiarize yourself with the project. It's always a good idea to read through the instructions before you begin to make sure that you understand everything, that’ involved, Tools and Suppl ies ae : AG S ae! ; \ amps. Fretwork Boxes Fretwork projects, boxes included, are often characterized by their large amounts of inside cutsand their sometimes delicate and difficult look. These boxes range from simple to more challenging, and they can be both functional and decorative, Gentleman's Box, by John A, Helsan, page22, 12 Creating Wooden Boves on the Scroll Saw « Fretwork Boxes Eee Swan Lake Keepsake Box Elegance and grace are always in style By Diana Thompson HE ceamrnnc rune Gamping spare blocks to the work pice helps hod it steady andlevel while cutting. Attach the dams only ‘ight enough to fold the work and nots tight thatthe blade cannot move through the kerf 1 often find ereative inspiration in common items we see every day but take for granted, was doodling with a drawing program on my computer when | realized | could make boxes in a variety of styles and sizes. Boxes, p are fan to make, They are also great gifts with that Photocopy the patterns. fo make thebos, begin by spraying handmade, personal touch. ‘he pattern for the borsides with ternperay bondspray adhesive. ~areFully coriides the lype Gt WOGd yO Want GEE. ‘Attach iCto the 4 to 1 stack. Use adil wite a ¥a"-dlameter bit Cecil ebb tne yee Gf Wa Ls tomake blade entry holesin each opening, Alarger bit, suchas one ‘with a" dlameter can aso be used, New scrollers may want to try basswood, white pine, sugar pine, or any kind of cedar. Remember, the softer the wood, the easier it is to cut. I made the box you see in the photo from genuine mahogany toes Cut the inside ine. Thread the 87 blade dough the entry ‘Sand the underside smooth. Use 220-giit sandpaper. holes and begin cutting. Cut only the inside line tobe cutlaterDo natemavethe pattern WE Greating Wooden Daxes.on the Scroll Saw ~ Swan Lake Keepsake Box margin around the edge. Approximately sx camps are needed Only two are shownbere for darity, Allow the gue tod at east anhout Cut around the outside line of the box sides. Use the #7 ter bit, Dae, You re now cuting through both thicknesses. edge of the box, | used rotary tool ited ito a router table attachment. Thisstepcan alsa bedane by hand with sandpaper. Making the Lid Ld andiid underside are cut and ready to giue together. ut the lid, Cut to pieces of 1 7" x 6" stoc. Aare the Vid and tid underside patter. If youuse plywoad,be sure both id pattems are adhered the good sides the unfinished sles oft pipwood wil be glued together, leaving the ood sie showing. Ot Dladeentiyhales inal frets ofthe ld's upperside and underside with 2 Y/-dlameter bit Thread a¥5 reverse-tooth blade through the hole and cut out only theinner line, as wasdone in Step 2 Creating Wooden Boxei.on the Scroll Saws SwamLake Keepsake Box) 15 Give the two lid sections together with the pattern sides facing out. Ciamp the two sections inte place asin Step Sand allow them ta dy or at least an hour, About sclamgs ate needed (Oni two are shown for lay. When the glueisdr ‘cut around the centerline and tower oftthelid undersideasin asin Step7. Step6. Youre cutting through both thicknesses Round overthe u yes ofthe lid jee. Cutout the handle pattern with scisors and foldit along the dashed line, Apply temporary bond spray adhesive to the back ofthe pattern and wrap it erourd tivo sides ofthe 4x 1'x2" wood. Drila blade entry hole in theelt side wing a Se’ diameter bit Tapetthe block. Allowing the figurete rest naturally in ‘sow table toensurethe theblock gently pinch thesides figures ush inside together and ape arounditwith the Blok, 4 cellophane tape. Tap the blockon the 16 Creating Wooten Daxes on the Scroll Saw ~ Swan Lake Keepsake Box Cut the handle. Three the 85 bade through the entry hole. ‘atthe side fet first, leaving it in place. Then cut the outside ines Cutthe left side. Finish the box. Aply 2 wood sealer tol pieces. pretera water-based eae de tothe easy deanup. However, wil ase the grainabit so ater the sealers dy sand the bxsmanth with 220 it sandpaper and fini with #00000 ste! wool. Glue the handletothe ba lid Apply several catsof dea fish. use kyon spray becuse doesnt caclr over tne Lid Underside Materia +1 plece, 16 1H x wood of chole (bx sides) +3 pieces, 6° x7" x6)" wood of choice (box bottom and lid sections) + Ipece, Mix 1x2 wood of choice (handle) + Temporary bond spray adhesive + Weod oe + Sandpaper, 220grit + #90000 stee woo! + Weod sesler + Gear finih ofehoice + #5 blade, #5 reverse tooth bade, and #7 blade + Dri with ie and as-lameter its + Rotary tool and 4" diameter round-ove bit optional) + 6damps Photocopy at 100% Creating Wooden Baxek.n the Scroll Sawn SwwamLake Keepsake ox) 17 Potpourri Box This attractive potpourri box quickly converts toa tea light candleholder. By Sue Mey Nothing makes a place smell more like home than potpourri, but it tends to get everywhe if you have furry friends. 1 the dried flawers and herbs where they belong. use a potpourri box. This potpourri box with lid was inspired by celestial bodies. Estack cutt the pattern and made ane in hardwood and another in medium density fiberboard (MDF), which Ipainted. ‘The item can also be used as an attractive tea light or flat candleholder without the lid. Do not place the holder in a draft, which could bring the flame into contact with the wood, Constant supervision is advised Step 1:Sand all hardwood pieces. Use a palm sander with 320 grit to sand both sides. This reduces the hand sanding after cutting, MOF does not require pre-sanding. Step 2:Attach the patterns to the ‘wood. Photocopy the pattern pieces at 100% and attach them tothe wood using temporary bond spray adhesive. Or, for simple pattems such as these, I like to transfer the pattem to the work piece with carbon paper and a stylus. Keep the pattern in place with two small pieces of masking tape. Step 3: Tape two or more blanks togetherto stack cut the box. To create multiple boxes at once, attach extra layers of wood or MDF tothe piece with the pattern on kt Use small strips of thin double-sided tape at the corners to hold the layers together, Note: The lid liner can not be stack cut because it will be attached to the lid before the pierce cuts are made. They can, however, be stacked for the disc sander process (see Step 8), before you attach a separate pattem to each lid tiner, Scroll this box to hold aromatic potpourri or watch a candle flame dance through roe raed the idor leave unattended Cron eet ics Step 4: Drill the blade entry holes. Use the /x"-diameter bit for the box sides and the /'-diameter bit for the features of the sun pattern. Note:Do not drill the lid liner blade: entry holes at this time. Step 5:Remove the burrs created by drilling the holes, Use a scraper blade at a slight angle along the grain of the wood, Ed serror cou ‘you detdero make the painted MOF bar, spatter alittle bit of gold paint on thebox toad texture, Working fast, spray somegold paint ante pape, dp an old {toothbresh into the pant, and una plastic ‘ruler aver the brush, Vary the direction of thespray onto the Box to.avoid uniform splashes. Or, fyou dan"t mind getting ‘Paint on your fingers, dip your middle Finger inthe pant and fick the paint randomly on the bo. Creating Wopdlen Borex. on the Scroll Saw. Potpoure}Box 18) AStep 6:Make the inside cutson ‘the four box sides. Thread the #5 blade through the blade entry holes and make the inside cuts of the box sidles—you can stack cut two layers at the same time. Use a #3 blade for the sun's features, Note: Do not cut the lid liner at this time. ‘A Step 7: Cut the sealloped edge ‘of the lid and base. To do this neatly, cut into the sharp point from the edge. Back out of the cut, and then cut into the sharp point from the other direction. A Step 8: Square the edges of ‘the sides and lid liner on the die sander. For this project, edges should line up nicely, and I find using the disc sander much easier than attempting to cut perfectly straight eciges with the scroll saw. Step 9: Separate the ‘wood layers. insert a scraper blade between the work pieces to pull them apart. Remove the sticky tape residue with a rag and some mineral spirits. Allaw them to dry. 4 Step 10: Apply wood glue to the back surface of the lid liner. ‘Then, center the liner on the inside of the lid. Clamp the four comers and the center. Remove excess glue ‘with a damp rag or toothpick. Once dry, apply/copy the pattern for the pierce cuts, ifnot done earlier. Drill blade entry holes and make the cuts Step 11:Sand the hardwood pieces by hand. Use 320 grt, after temoving the patterns, Then, switch %0500-grit to get a smooth finish, Only lightly sand the eut edges of the MDF to remove any burrs. Step 12: Gluethe box. First, remove all sanding dust. Dry-fit the four box sides on the baseto ensure all edges line up nicely. fneeded, mark any adjustments and sand them to shape. Apply wood glue to the boxsides, one ata time, and place them on the base Hold the fotir box sidesin position with both hands. ‘Then, center them on the base and press down hard. Exert equal pressure fon the sun and moon face sides to ensure the moon and star sides are firmly attached. Remove excess glue ‘with a toothpick or damp rag. ido not use clamps, butyau may need to use them depending on the glue youchoose. For the hardwood box, apply a deep penetrating furniture wax Tiquid with a medium-size artist's 20, Creating Wooden Boxes on the Scroll Saw = Potpourri Box AStep 13: Apply the finish. brush. The brush will reach the nooks and crannies of the pierce ‘cuts. Place the box and lid in the sunto dry. If this is not possible, allow day or two before vamishing. Wipe all box surfaces with a dy, lint-free cloth. You can also apply Danish oil according to manufacturers ditections For the MDF box, spray the inside and outside of the box and lid with several thin coats of spray paint, allowing it to dry completely between coats, Remove spray paint from fingers and utensils with lacquer thinner. A Step 14: Apply the final finish. ‘Apply several thin coats of clear spray vamish tothe hardwood ‘box, allowing it to dry thoroughly between coats, The painted box does not need to be varnished. the box with your favorite mix of potpourri, replace the lid, and place itnear an open window to disperse the fragrance into the room, Alternatively, light a fragrant tea light and place it inside the open box. Note: Never use the lid with a candle—and never leave a burning candle unattended! wari Four the wax liq into an old ceramic ‘mug and heat it in arnkcroware oven for 1S seconds, Tis allows the wax toiquely and penetrate the wood without leaving a ‘wary layer. UP WAX Metetts ees pide SWaT2X 38" hadmoodotthoke Quid dy wood gle or MF (bx sds) +Danprigorremaralot excess gue +\sa8'xf'hordwoodefchoce Dep penetrating future wa uid ox 0 (basa ie) ‘orDansh land anatst sash *WraZiA2W'ardnoedofehoke Cer spayvamish or MOF Ciine) mre =Sandpaper assorted atts +S revesetothblode erpronbonisieteieer an eerste cabonprperandsts -Dilpress wth and + hin cublesettpe ee oie 53 paint of coe Dsesanderand aim sander res a =a Back x JZ a “> \s os LP Lid and base (outer line only) ao Lid liner Front “ Photocopy at 100% Creating Wooten Boxeson the Seroll Same Potpourri Box y) 21 Gentleman’s Box ‘Thiswalnut reprodu ‘of abox crafted inthe {ate-1900s wil ft into any collection. {found this beautiful, simple box in an antique shop along Route L, just south of Kennebunkport, Maine. “The original was made of walnut. A silk lining was first glued toa cardboard backing before bath were glued into the box. Step 1: Choose wood with an interesting grain patter. | suggest walnut, maple, or black cherry. needed, glue up material tomake the lid and the battom. Cutall of the wood to size using the provided materials|ist. Step 2: Cut a6* bevel onall four ‘edges of the top to knock off the sharp comers. if you are confident cutting the bevels on the scroll saw, simply tittyour table down 6° Alternatively, you can sand the bevel tusing your sander of choice. These bevels are just embellishments that appeared on the original—you can make a boxwithout the bevels if youwant. Step 3: Sand all the surfaces of the top. Be careful not to round over any edges, 22 Creating Wooden Baves on the Scroll Saw = Gentleman's Box Crores ofthe wood, itis easy to eed proeees Step 4: Cut the bottom ta the exact size. Put a 30° bevel on all four edges. Use the techniques explained in Step 2. Again, sand all ofthe surfaces of the bottom, but be careful not to round over any edges. Step 5: Cut all four sides to size. Cutan exact 45° bevel for the miter joints on the sides of each piece. IF you dont have a table saw to cut the miters, use a disk sander with a miter gauge. Set the miter gauge to 4S* and slowly sand the edge down tothe proper miter. You can cut the miters with a scroll saw, but itis difficult to get the miters to fit tightly Step 6: Use masking tape to tape the four sides together. Make sure all the joints fit together exactly (see Making Miter Joints) Step 7: Cuta sub-base to fit tightly inside all four sides. This helps the box hold its shape. Plywood is recommended to reduce any expansion (or contraction) in ‘one direction, The sub-base can be embellished with fet, locking, or silk Step 8: Remove the tape. Then, sand the top and bottom surfaces of the sides. Step 9:Markand notch ane side forthe hinges as shown onthe pattern. Re-sand that side, which will be the back of the box, te make sure it’s smooth. Step 10: Prepare the lid. Center the lid pattern on the top andattach it using temporary bond spray adhesive. Then, drill blade entry holes to make the interior cuts, Step 11:Cut out the pattern. Use a #20r #3 blade or your blade of choice. Step 12: Sand the top and bottom surfaces of the lid. Use fine-grit sandpaper. Step 13: Prepare the three copies of the side pattern and attach them to the right side, eft side, and front blanks using spray adhesive, Do not attach a pattern to the back piece, which was notched for thehingas. Step 14% Drill blade entry holes and cutout the fretwork on each side. Alternatively, stack all three sides together, and wrap all four edges with masking tape. Then, you canstack cut three sides at once. Step 15:Sandallof the sides’ surfaces with fine-grit sandpaper. Step 16: Apply wood glue to the 45° miter cuts on all four sides, Using the masking tape technique explained in Step 6, assemble alll four sides, and allow the glue to dry. Remove any excess glue, Step 17: Center the four sides on the base and insert the sub-base from the top. Predrill holes from the Base into the sides, and insert tiny brads for a permanent assembly. Step 18: Apply the finish of your choice. Step 19: Attach the lid with two brass hinges. Again, predrill the holes for the screws so you dont split the wood. Step 20: Cut cardboard to fit the four sides and lid (optional). Add silk felt,oryour covering of choice to the sub-base of the bax (optional). You can also paint the cardboard and glue it in place. The original had sik glued to the cardboard liner on the four sides and lid, Alternatively, you could add flocking according to the manufacturer's directions. MAKING MITERJOINTS There are several ways to fue upc miter joint bax. Far beginners the easiest way to use the tape methed, Start by cating four lengths of tape slighty shorter than the helghtof the Box Copproximately 3). Place thetope face upon the workbench and sticksde one ofthe boxto the tape. + Dpieces Yin 991 94" choice (top and battom) pieces ¥ie"'x39i¢ x84" hardwood of cheice ides) Me x87 x86 plywood ofehoice (sub-base) + 2bass hinges, Max 1" +12 brads, Sa" long + Skbacking over cardboard o locking ofehoice + Wood finish of choice + Wood glue Masking tape + Repositionable spray adhesive Tools: +43 blades or blades of choke Del with eter ill bit + Assorted grits of sandpaper ‘Align the edge osde two exactly alongside the edge of side — ‘one (see diagram) and press both sides firmly aginst the tape. Apply wood glue to alte Joints and bring side four back oround to join ide one. Check to make sure the bax s square ‘sing a square to check the outside corners or by inserting the sut-base into the Dox. Creating Wooden Boxes onthe Scroll Sew y, Gentleman’ Box 23 Renaissance Keepsake Box Mu: or jewelry box features an intricate filigree design By Rick and Karen Langabaugh Cut by Ben Fink Handmade gifts make a lasting impression, This vintage-inspired keepsake box is sure to impress even the most discerning recipient, Choose a musical movement that plays.a tune with a special meaning or leave the bottom solid so the intended recipient can use it asa trinket or jewelry box. ‘This box is made from Honduras: mahogany, but a-variety of woods are suitable. Cut the pieces to the proper dimensions. Cut the fretwork design in the lid before cutting the perimeter, Stack the top and bottom together to cut the scalloped borders at the same time, If you make small errors while cutting the perimeter, the two pieces will be identical, and the mistakes will be less noticeable. Stack cut the longand short sides, to speed producti 25 Creating Wooden Boxes on the Scroll Saw = Renaissance Keepsake Bax This project makes. a beautiful gift whether you add a musical movement or present itas a keepsake box. Ifyou are installing a musical movement, drill the %"-diameter hole for the music box key where indicated on the pattern. IE presenting the box without the musical movement, the feet to raise the box are optional, Cut the feet using standard compound-cutting techniques. After cutting all of the pieces, glue all four es to: the bottom using, the dotted lines on the pattern as a guide. Tabson the long box make alignment casiet. Glue the feet to the bottom of the box. Apply your finish of choice to the assembled box and the lid. Then, install the music box mechanism and attach the lid to the box using small brass hinges. Use thin plywood or cardboard wrapped in folt for an optional lining behind the fretwork sides and lid, >A D>aaan eee ee | ae a | tel Pn Ban a a a a as so a Se a Sa se ne ee ee Sees ese ee ee ee ee Me S| posn epsrewjo “su 04" AeEs020U 3915 50fpY oq anu jo vonisod ‘se1e2ypay8uy pauicg Photocopy at 100% Creating Wooden Boxeson the Scroll Saw ~ Renaissance Keepsake Box | Se Sgr eH OOO) AS pm ega ee g | SSA Oe ye : feo [eee fete Me @ as OO HeOOR| | Rea, 41D NY iy EE SEG) | peas RIO) MK I be Oe 2 EOS : fs se) | <> Di sZpieces\0 x71 1 woadof choice «es pina to hol des together pees VOOM . es Bae Settee Ome (id and bottom) i ee Tools i =e s4pecs A MHA WoO! AT rereriooth Hades aa | choice (feet) corblades ofcheice Mihai oN sm options) owen Ya and with matching diameter dui bits Screwdriver t instal + Resorted gitsof sandpaper smal brass screws “Temporary bond spay adhesive ‘Hammer (optional) “ocd glue ‘Brushes to apply fish of chice (optional) Photocopy at 100% (Creating Wooden Boxes othe Scroll Saw: Renaltsance Keepsakes Bx 2, Victorian Fretwork Music Box Classic details provide This handcrafted music box is sureto become a animpressive look, _ ‘!tished family heirloom. Even without the musical Bit this uinkage b movement, the project makes a beautiful keepsake box. ut this vintage Boxis ty experimenting with different options—Hine the surprisingly easy to scroll inside with silk or try abacking board with flocking; se _y, _ Sctall just the top and leave the sides solid. You could ByRickand Karen Longabavgh every alter the pattern on the lid to include a monogt oo special symbol. Customizing the box makes ita one ofa-kind gift that is sure to please. 20° GreatingWeoclen Boxsseon the Scroll Saw ~ Victorian Fretork Music Box ‘Step 1: Prepare your blanks. Cut all ofthe pieces to the dimensions Tisted in the materials Hist Sand all of the pieces with progressively finer grits of sandpaper up to 220 grit. Step 2: Prepare the side pieces for stack cutting, Stack the two blanks forthe long sides and the two blanks for the short sides. ‘Attach the blanks together to stack cut. using your method of choice (painter's tape, hot glue, double- sided tape, etc). ‘Step 3: Transfer the patterns to the top, bottom, and side stacks. Use your method of choice (temporary bond spray adhesive, carton paper, or graphite paper) Fold the patterns for the feet along the dotted line, and attach them to the blanks using temporary bond spray adhesive, Step 4: Drill blade entry holes forthe interior cuts on the top, sides, and bottom. Use the sinallest drill bit that a #1 blade,or your blade of choice, will i through. Drill the 4"-diameter hole in the bottom for the music box key. Mark and drillthe pilot holes for your hinge screws at this time as well. Step 5:Make the interior cuts on the sides and top. Startin the center with the #1 reverse-tooth blade and work your way out. Cut the slots on the bottom for the side tabs. Ty to keep these slots os square as possible so the side tabs fitintightly. Step 6: Cut out the perimeter of the top, bottom, and sides. Use a #5 reverse-tooth blade. Iti possible to stack the top and bottom together, using double-sided tape or hot glue. This way, the scalloping around the edges will be exactly thesame. Step 7: Cut out the box’s feet, You only need to cut out the rear view on the scroll saw since the top view is the exact dimensians listed in the materials list, Use a #5 skip- tooth blade, The piece is very thick (1)4*-thick), 50 use caution, and let the saw cut at its own speed. If you try to cut too fast, the saw blade will bend, and you will get an angled cut. Step 8:Sand the pieces with 220-grit sandpaper to remove any burrs. Apply your finish of choice. A good choice would be to dunk the pieces in Danish oil or boiled linseed oil. Bunk the pieces, bring them out, and suspend then so the cil will drain off Step 9: Assemble the box according to the assembly diagram. Run a bead of glue along the ends of the short sides, and nail the pieces together with small brads where indicated on the pattern. Glue the tabs on the long sides into the holes in the bottom, Make sure the screws for the hinges are not solong that they will penetrate through the wood of the top and side. Then, attach the hinges Step 10: Glue the feet in place on the bottom where indicated on the pattern. Use your wood glue of choice, and clamp the pieces overnight, Attach the music box movement to the bottom where indicated on the pattern. Follow the manufacturer's directions to install the music box movement, jes ie + 2pveces)6 x8» 1A" woo of owe (op ‘and bottor) + 2pleces "x DH? x96 wood afchoke (ides) + 2peces 4" x 24° x54" wood of chee (ends) +A pieces "x T°x2" wood of choice (fet) hinges, 14°" with correspanding screws + 8small bra to tack sides together Sandpaper, assorted grits up 19220 get Wood glue of choice Flush ehoiee + Musicbox movement of choice To! + #1 and #5 reverse tooth blades oe Blades ofchoice +5 shp-tooth blades or blades ef choice ral + Assorted smallciameter dil its 24" dlameter dil bit Hammer nail n brads -Clamps.ofcaice Creating Wooden Boxeson tie Scroll Saw = Victorian Fretwork Music Box )) 31 J fi ; eee | er =< Re ESS NS 8 eee i at oe) ae iS | = | oe NF Z ys | Good Luck Box eC On rane design patterned after a Victorian box Dea The idea for this project came. from abox my son picked up at an antique store, They called it a The top ‘was hinged and the wear and tear from opening the box had cracked the back where the hinges were fastened. That is why Lopted to make the top completely removable, I believe the original box was cut out of mahogany, but there were so many coats of finish on it, Tin not sure The original box was not lined, but | added a flocked interior. | did change the dimensions of the original box a little, but kept the spirit alive. Tused Baltic birch to make my box, but it looks good in black walnut with red flocking and black cherry with brown flocking. See Victorian document bos what other combinations you ean create, Step 1:Cutall the wood to size. Atable saw works best to give you straight sides and sharp corners. Step 2: Cutthe box joints. You can cut the joints on the table saw, with a router, or on the seroll saw. IFcutting joints with the scroll saw, apply the pattem to corresponding pieces now; it is best to cuta little proud of the line on a scroll saw and adjust the fit by sanding, lused a seroll saw on the prototype and would highly recommend using a table saw or router. They make a much better joint. Step 3: Cutthe scalloping on the top and bottom pieces. Nail both pieces together in each comer for stack cutting, Attach the pattern to the top piece using temporary bond spray adhesive. Using the #7 blade, cut the scalloped outline an both so they will be uniform when finished, Take your time—the wood you eae Ceenieerieriet are cutting is both thick and hard. Designate ane as the bottom and the otheras the top, Step 4: Prepare to cut the fretwork sides. Start by attaching the pattems to the wood with the spray adhesive. Then, drill blade entry holes for the fretwork on each panel Step 5: Cutout the fretwork onthe top and sides, Start in the center and work your way outward coneach piece. cut it all using a #5 blade, but some people may prefer finer blades for the more fragile fretwork. Step 6: Finish sand the pieces using fine sandpaper. If using a power sander, curl the edges of the paper up se they donot catch on the edges of the fragile fretwork ‘Creating Wodslen Boxes on the Srp am) Good Lael Row) 25 ‘A Step 7: Glue up the box sides. Make sure the joints are sanded flush. Then, apply glue to the joints, clamp, and allow them to dry. ‘A Step 8: Spray the top keeper and inside panels of the box. Use flat black paint on one side only. Allow ther to dry. ‘A Step 9: Glue the inside panels ‘onto the box. The color should show through the fretwork. A Step 10: Glue the keeper to the top. The color should again show through the fretwork. Allow everything to dry. Step 11: Spray everything with several coats of aclear finish of your choice. Be sure to spray the inside to seal it before adding the flocking. Alloveit to dry. A Step 12: Apply tape. Tape around the edges ofthe box and along the edges of the keeper to contain the flocking. Photocopy at 160% A Step 13: Apply the undercoat adhesive for flocking. Then, apply flocking. Do the top first. Then, move ‘onto the box interior, Allow the box to.dry for 24 hours. Step 14: Remove the masking tape and replace the cover. Lea Front/Back lu Ul 36 Creating Weoclen Doxeson the Scroll Saw - Good LuckBox een choice é ring & bas) a delicate Pee eae sy) oe aE 7 ony EtEAS) : IE OO cS we OCA S (Ges 3) paw So Neat n Creating Woddlen/Baves on the Scroll Saw Good LuckBox 37) ee (aval He 2VLAN z ele = be eee as ee Walnut and Brass | Keepsake Box Provide a safe harbor for your treasures and heirlooms with this attractive and versa' keepsake box By Joan West (Our “collectible” memories can beas shiny as brass and as warm as walnut. This project is a chance for yont te discover your scroll eaw can ct eaore than ygaagi wood. Moreover, it enables you to experience the joy «yi 12°10" walnut #7 blades for metal ng with brass to create a lasting tribute to (base. layer) + £T precision ground tooth those persomal keepsakes you hold so dear. 4x1" 9" walnut wood blades The soft brass plate used in this project was (ox wal er 2) ‘Jhe-dameter eit bit ordered fram Showcase Brass Company Ine., =¥'x11'x9" walt lip, iyer3) «Smal chisel but a standard door kick plate purchased from a 12! 10" walnut = W-radius round-over router bit local hardware store will work nicely. Scrap and. anes Silicon spray bubricant ‘unpolished brass are also workable if you want CRATE AY ee OP Le Cake or x 88" 1614 scrap wood to invest in a can of brass polish and a little + Temporary bond spray adhesive elbow grease. Te emonmate smile c00-ont sandpaper tor bash 1d sized the initials specifically for econ ae this project to compliment the unique, decorative pan ei nature of the brass pattern. Please feel free to sDanishod SCI use similar monogram styles of your choosing or Seen peter whatever ornamental stencils or computer fonts SiRbn onder Ger packaging that strike your fancy. ES + Retry polishing tool foptana) 38 GreatingWoodlen Boxeson the S

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