How
to Cut Your Box:
- Cut your box from a
solid block of hardwood to the outside size and shape you want using a
band saw. A 1/16th blade works well to cut the "Keys" if you
work on a small project as
you must make a tight circle but on larger boxes the 1/8th is fine.
- Sand smooth--Sanding
all parts as you go will make it easier and will seem quicker
- Cut a thin slice
approximately 1/8 inch off the bottom and set it aside until all parts
are cut. This will be the bottom of the box (diagram A)
- Cut Key #1 as seen in
diagram B. Be sure to cut in bulb shape or it will fall out of
the wood. Remove it and set it aside before cutting Key #2
- Cut Key #2 as seen in
diagram C. This key forms the lid of the box. Remove it
and set it aside before cutting hole in center
- Cut out the center of
the box as seen in diagram D by entering through the end
keyhole. This hole is cut all the way through. When you
cut this piece the lid is still off, the bottom is still off,
and the key is out. If this center cutout piece is large
enough--save to make another box or discard if desired
- Glue the bottom
section back on the box
- Do your final sanding
and use your favorite finish to complete the project. Wood
carving can be used to decorate the box if desired. Slide the
lid on the box when all parts are dry and then insert the magic Key #1
to secure the lid
- All puzzle boxes are similar and are cut step by step in this manner.
This is the BASIC box. It is imperative to cut the round bulb
section larger than the neck of the bulb at the start of the cut,
otherwise everything will fall apart.
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Diagram
A Step 3--1/8 inch bottom |
Diagram
B Step 4--End Key #1 |
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Diagram
C Step 5--Lid of box and key #2 |
Diagram
D Step 6 --Hole in Center for trinkets |
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 Re-assembled
Box
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Return
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