td SCROLLSAW
“ caERTTE WOODEN
BOXES
onthe Scroll Saw16 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
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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 2009Table of
Contents
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r Nesting Basket THO ensue. eatmneer TT
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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 63Keepsake 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 = IntroductionScroll 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 BoxesEee
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 Boxmargin 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) 15Give 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) 17Potpourri 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 WAXMetetts 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) 21Gentleman’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 cutthe 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 23Renaissance 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
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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 )) 31J
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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
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Creating Woddlen/Baves on the Scroll Saw Good LuckBox 37)
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(aval He 2VLAN z
ele =
be eee as
eeWalnut 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 Fantasy Kesprake Bees. 57I
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ay
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‘58 Creating Wooden Boxes on the Scroll Saw = Fantasy Keepsake BoxesHanging
Backpack
Box
Segmented sections
and rich colors create
arealistic look
By Sue Chrestensen
eee
Materials:
S117 x36" pine
(segmented id andbox sides)
Wx Dx Bate birch pywoed
(acter board and box beter)
SW x2"x2€ wood of ehoice
(hanging board for pegs)
+} wooden shake pegs,
=dametes x?”
+ eelameter dowel
Latch hook
+ Termporary bond pray acheive
+ Biv painter’ tape
+ Marker to number the pecs)
Weed glue
+ Sandpaper, 129, 160,8 220s
+ Stan de tcolorthe wood
(eptona)
This coat rack is a fun and functional project that looks great in a+ Asorted pants
hallway or kid’s bedroom. The inside of the backpack ean have a + Vasnish (optional)
mirror, shelves, or hooks to hang jewelry.
‘The outside of the backpack can be any color, and any flaws in eek
the wood will just give it a used look. Imagine a well-worn, often coffers aces ot ours
used backpack—add some dents and curves where you think they Pee
belong and give this project character and unique qualitics based #2” ¥8#-dameter doll bit
oon your imagination, oes eet
down stoi)
+ Rotary tol and assorted carving
burs optional to estucethe
seorentation)
+ rio dil pess
(62 Creating Wooden Bones onthe Scroll Saw ~ Hanging Backpack Box 'Step 1: Cutaround the perimeter of the pattern.
‘Then, find the interior lines that will let you divide the
piece into manageable sections. cut along the flap line.
Keep asmall piece of sandpaper handy to remove any
burrs generated by the cutting,
Step 2: Cutout the segmentation pieces. Label
‘a master copy of the pattern and the bottom of each
piece with a number for easy assembly, Remove the
pattern—the longer the pattern remains on the wood,
the more difficult itis to remove, Place each piece inthe
corresponding location on the master pattem.
Step 3: Makea
je and cut
‘out the backer
beard, Use the
segmentation pieces
todraw the template
for the backer
board. The hanging
strap portion of the
segmentation isnot
attached to the top
backer board but is
glued directly tothe
box sides. Do not
include this section in
your pattern for the
backer board,
Step 4: Glueand clamp two pieces of pine together
for the box sides, Temporarily stack a piece of plywood
tothe bottom af this section for the box bottom. Transfer
a complete patter to this blank. Cut around the outside
‘of the pattern and the inside of the hanging strap.
Step 5: Cut the inside of the box. Remove the
plywood layer and the pattern from the pine box sides,
Draw aline approximately '2" inside the perimeter of the
pine box sides blank. Drill a blade entry hole, insert your
blade of choice, and cut out the inside of the box. Glue
and elamp the plywood box bottom onto the back ofthe
sides, letit dry, and sand the assembly for a good fit.
Step 6: Shape the segmentation pieces. Use a hand
held rotary tool or a power sander, or shape the sections
by hand sanding. Remove a fair amount of wood from
the pockets and flap on the backpack, Sand these areas
‘smooth. This gives the appearance of a fold and implies
that the leather is soft. Sanding the eciges of all of the
pieces gives the project a finished and coordinated look:
the pieces flow together, yet are very distinct. Shape the
hanging strap segmentation pieces at this time as well
Step 7: Position the segmentation pieces-on the
backer board. Arrange the pieces on the backer board
and cut shims for any sections you would like to raise.
Shims should only be used on inside pieces. You do
not want them to show and detract from the project.
Complete any final shaping of the segmentation pieces,
to achieve anatural flow.
Step 8: Color and finish the project. Finishes on
any project area matter of personal choice. The key is
to put as much energy and effort into the finishing as
you did the rest of the project. | use leather dyes to color
my backpack. To distress the finish, sand different spots
with 220-grit sandpaper to make some lighter areas, Use
‘metallic paint for the buckles and acrylic washes for the
pencils. Finish the base of the box as well
Step 9: Glue the segmentation pieces to the backer
board. Arrange all the pieces on the plywood backer.
Remove one inside piece, apply a small amount of wood
glue, and return itto the original position, Clamp the
piece in place, and allow it to dry overnight. Continue
outward from the center piece, removing, gluing, and
clamping pieces ftom the inside taward the perimeter.
Glue the segmented pieces for the hanging strap directly
onthe box sides.
‘Step 10: Assemble the box. Drill the hole for the
dowel that will hold the top to the box. Drill a hale the
same diameter as your dowel halfway through the pine
box and halfway through the segmented portion and
backer board of the lid, Cutthe dowel to ft, letting the
top of the box lie fat. Glue the dowel into the bottom
box. Attach the latch hook onto the left side of the box
with small screws. Sign the back of your project.
Step 11: Create the peg rack. You can usea
commercial peg rack or create your own, Drill holes the
same diameter as your pegs into a length of wood and
glue the pegs into the holes. Attach a hanger to the back
of the coat rack board. Hang the backpack onthe coat
rack board with the peg going through the strap opening
‘on the upper left-hand corner.
Creating Wooden Boss onthe Scroll Say Hanging Backpack Box.» GE