MAKING  A  SMALL  PUZZLE  BOX

by  CAROL  ZANDELL

 

How to Cut Your Box:
  1. 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.
  2. Sand smooth--Sanding all parts as you go will make it easier and will seem quicker
  3. 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)
  4. 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
  5. 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
  6. 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
  7. Glue the bottom section back on the box
  8. 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
  9. 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.

Diagram A  Step 3--1/8 inch bottom

Diagram B  Step 4--End Key #1

 

Diagram C  Step 5--Lid of box and key #2

Diagram D  Step 6 --Hole in Center for trinkets

Re-assembled Box

Return


HOME | SHOW & SALE | CLUB INFO | V GALLERY | EVENTS-CLUBSCARVING FAQ | LESSON | LINKS

REGISTER CLUB | GALLERY | WEB WOODCARVERS | PROSPECTUS | VENDORS | FORUM

.Created Oct 2001....updated FEB 2017