Making a large pen box

In 2013 I was making small wooden pen boxes for fountain pen enthusiasts. I was asked if I could make a large case.

The first step in this project was to decide on the size of the box. To do this I started with the size of each pen or group of pens in each tray. With a little bit of trial and error I was able to work out the sixe of the trays and from there the required box size to put them in.

I mapped out the box size on a piece of plywood and chose 25 mm oak which my timber supplier helped me with the outside sizes and I cut the mitres.

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I added a strip of walnut around the top which will form the lid I added another piece on the bottom which I you may have guessed will form the base.

The top is plywood edged in the walnut with a walnut burl insert.

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I then planned the edges of the walnut down level with the veneered top.

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Once I had added the top and bottom pieces I had to cut the box into two parts after all of this work this required a very deep breath.

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In order to add extra strength I cut some holes and inserted some key pieces which I glued in place.

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After adding the keys I also added some magnets to act as closure mechanisms

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Now adding these keys and magnets made the inside edges of the box look untidy my solution was to apply an oak veneer to these edges.

After some searching I found these gold plated hinges with a built in stop to prevent the lid opening too far.

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Bringing all of the components together and we have a box with a hinged lid.

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Now the box is complete I started to focus on the inner trays these are made by cutting the four sides and mitring the ends. I laid them out end to end and applied masking tape over the joins I then applied glue to the mitres before folding them up and securing the final end with more tape.

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Once the glue had dried I used a mini router to make a grove in the bottom of each of the three trays to allow a piece of oak veneered plywood to be added as a base.

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The two trays for smaller pens had a centre divider the third tray for the larger pens did not have a divider.

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I now had a base and three trays

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Each tray now needed inserts which I made by gluing pieces of dowel to card and covering in suede.

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I also applied suede to the inside of the box

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Here are the three trays with the finished waxed box.

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Finished and ready for delivery.

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Thanks for looking

Michael

 

 

 

 

 

 

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