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Barrel Hinge Boxes by Richard Anthony (rmartin) Continued from PAGE 1 Mortising the Box Cavity

Make a frame for the box. It should be wide enough for a router base to operate freely. It should also be the same thickness as the box. Strips of 1/8" plexi-glass are screwed to the frame adding 3/8" overhang to the inside of the box cavity. This will create a stop for the router.

Place the frame over the box. If there is any play at all, use shims from underneath. Clamp the frame to shop table.

A router is one of the most versatile shop tools. Here, a brass collar has been added. They are available for most router brands. A straight edge mortising bit is installed.

Start by taking no more than a 1/4 inch. Everyone mows the grass a different way. I go around the edges and then pull the router towards me one row at a time. Make several passes until the desired depth is achieved.

A 1/4 inch round over bit is installed on a dedicated router table. All edges, top and bottom, inside and out, are routered.

Applying the Finish

Sanding is the most important part of finishing. No finish will correct a poorly sanded piece of wood. In fact, the finish will magnify sanding defects. I spent 2 hours on each box using a palm sander, block sander, and hand sanding with 120 grit, 220 grit, 320, and 400 grit. The end grain edges were shoe-shined with 600 grit.

In the images below, the boxes have been washed with a proprietary mixture of sanding sealer and stain giving the wood a tanned look. They were then sprayed with 5 coats of high gloss lacquer. After curing, they were polished with micro-mesh sanding cloth.

Installing Box Liner

After considering differents patterns and colors, I decided to go with a neutral grey felt. An elastic band is glued in at an angle. CA glue was drizzed around the outer edge, and rope piping installed. The rope piping was then drenched with CA glue. The rope piping dried hard and clear. Note: CA needs time to cure before the box is closed. Failure to do so will result in a whiteish powder accumulating on the wood and liner as the CA "gases off".

Installing the Barrel Hinges

By now you're probably saying, "Wasn't this tutorial about barrel hinges?" As I pointed out in the beginning, the trick is drilling the holes. Installing the barrel hinges is the very last step and it's a no-brainer. Use a little bit of epoxy glue and hand press in place. Adjust if necessary with lid in the open position and it's done. And now I'm done.

Comments and suggestions
rmartin@fountaincityfurniture.com