New lidded box

[Rusty Nesmith]

Making a surprise box for my wife. This one is a pretty good size one. I can’t remember the wood type. It is going to be a whiskey barrel. I used silver/grey miliput for the steel bands. I will use a thin plywood for the top with a cork for the handle.

 

[Tim Tucker]

You had me at whisky .....O.K. - let's go...now I have see how to do this.

 

[Tom Albrecht]

Making a surprise box for my wife. This one is a pretty good size one. I can’t remember the wood type. It is going to be a whiskey barrel. I used silver/grey miliput for the steel bands. I will use a thin plywood for the top with a cork for the handle.View attachment 46099

keep posting...

 

[Rusty Nesmith]

Today I turned down the Miliput, flocked the inside, made the lid and stained it all natural oak. Just need to get a good finish on the outside now.

 

[Tim Tucker]

Impressed! Can you blacken and hammer texture the rings. Maybe add drops of thick black CA for rivets? Just thinking out loud...not trying to make work for you Rusty...

 

[Rusty Nesmith]

Could probably paint some black dots like nails. Good idea.

 

[Tim Tucker]

I am always good at spending other people's time.....

 

[Pat Patterson]

I like this. I have a urn for my wife on my to do list. Could you share the Angle and width and thickness of the staves and the finished diameter and width? My wife loves Irish Whiskey. Needless to say I will have to check with her. Sometimes what I think is cool she thinks I am out of my gourd

 

[Rusty Nesmith]

I like this. I have a urn for my wife on my to do list. Could you share the Angle and width and thickness of the staves and the finished diameter and width? My wife loves Irish Whiskey. Needless to say I will have to check with her. Sometimes what I think is cool she thinks I am out of my gourd

I don’t remember the angle. I never plan too far ahead. I just figured out how many would work with a good angle to cut and started cutting. I wish I would have made them thicker so the barrel would have been more rounded on the outside. I will post some measurements when I get time.

 

[Tim Tucker]

Rusty - I think you just "prototyped" a really neat idea. This one was great -and your next one will be even better. Bing selfish here...I would love to see a step-by-step on how you did this - or a video.
I am a Jack Daniel's Squire - which is a interesting/fun bunch of crazies....So - you can see my interest in making one of these for myself.

 

[Rusty Nesmith]

I like this. I have a urn for my wife on my to do list. Could you share the Angle and width and thickness of the staves and the finished diameter and width? My wife loves Irish Whiskey. Needless to say I will have to check with her. Sometimes what I think is cool she thinks I am out of my gourd

Pat I am sorry it took so long to answer your question. There are 18 staves so the angle I ripped them at was 10 degrees. They were straight not curved. They were around 1” thick and next time I will go at least 1.5” so I can get more curve on the outside. The barrel is 7.5” in diameter and 11” tall. I glued it all together and had two open ends. In order to turn it I cut one end square on my bandsaw and then glued a board on it to attach a faceplate. It seemed very sturdy but put a steady rest on it to get rid of vibration. The recess for the miliput for the metal bands I would make thinner next time. I used the standard square carbide cutter to make these and they seem a little wide.

 

[Pat Patterson]

Pat I am sorry it took so long to answer your question. There are 18 staves so the angle I ripped them at was 10 degrees. They were straight not curved. They were around 1” thick and next time I will go at least 1.5” so I can get more curve on the outside. The barrel is 7.5” in diameter and 11” tall. I glued it all together and had two open ends. In order to turn it I cut one end square on my bandsaw and then glued a board on it to attach a faceplate. It seemed very sturdy but put a steady rest on it to get rid of vibration. The recess for the miliput for the metal bands I would make thinner next time. I used the standard square carbide cutter to make these and they seem a little wide.

Rusty,
No problem in the time. It's a roundtoit and hopefully I won't be loosing her any time soon BTW I really like the calabash you are making. Is it from a laminated blank or segmented pieces?

Thanks
Pat

 

[Don Wattenhofer]

The bands for your barrel could be made from any flat stock like backed veneer or even sheet metal. The bands on the lamp shades are made from phenolic backed walnut veneer. To calculate the arcs needed to lay out the band Google "Frustum (Truncated Cone) Calculator". When I made the bands for the lamp shades I entered dT of 4.44" , dB of 4.67" and h .487" ( to determine the h dimension I formed a right triangle with the base being 1/2 the difference between dT & dB or 0.115, and angled side being the desired 0.5" then solve for the cone height h = .487 then the calculator does the rest. To cut the veneer I bought a 1/8th" down cut router bit and with that bit in my router as a trammel point set at 10.16" + .0625 (1/16") for the outside and 10.16" - .5" & .0625" for the inside. The cone circumference c and the angle A designate the length of the band so if you want to overlap the ends just extend your cut. I spliced the ends using a scarf joint so it is difficult to even see the joint but you can feel a slight bump.

 

[Rusty Nesmith]

Rusty,
No problem in the time. It's a roundtoit and hopefully I won't be loosing her any time soon BTW I really like the calabash you are making. Is it from a laminated blank or segmented pieces?

Thanks
Pat

Thanks. I buy a lot of wood from a local sawmill. I bought a piece of walnut that was 2.5” thick and around 10” wide by 6’ long. I cut a piece of it in half on my bandsaw and glued a piece of 1.5” maple in the middle.