This stunning book-shaped keepsake box was designed by Steve Ramsey from Woodworking for Mere Mortals.
Materials and Tools
- Cherry wood (or your preferred hardwood)
- Maple wood (for the inner box)
- Wood glue
- Rare earth magnets
- Felt (for lining the inside)
- Spray adhesive
- Paste finishing wax
- Table saw
- Crosscut sled
- Push stick and push block
- Miter sled
- Drill with Brad Point bit
- Router (for chamfering)
- Sander (random orbit or hand sander)
- Clamps (or rubber bands)
Step 1: Gather Your Materials and Tools
Before diving into the project, ensure you have all the materials and tools at hand. This will streamline the process and help avoid interruptions. Using hardwood like cherry will provide durability and a beautiful finish, while maple will create a nice contrast for the inner box.
Step 2: Prepare the Spine of the Box
Begin by cutting the spine of the box to the desired width. This is a crucial step in achieving the right proportions for your keepsake box. Remember, taking your time will yield better results. You may want to cut several pieces at once for testing purposes.
Next, adjust your table saw blade to the appropriate height to thin the spine. Using a gripper will assist in making accurate cuts while keeping your hands safe. This tool will help you maintain control over the workpiece without the risk of tipping over.
Step 3: Shape the Spine with a Curve
To give the spine a classic book appearance, you will need to shape it with a gentle curve. Mark where the curve should end and use a sander to create the desired shape. If you do not have a specific sander, a random orbit sander will work just fine for this task.
After achieving the curve, round over the tabs at the spine’s ends to facilitate the opening and closing of the box cover. This is essential for smooth operation during assembly.
Step 4: Thin Down the Book Covers
The next step is to prepare the book covers. These need to be thinner than the spine, ideally around a quarter-inch thickness. If you have a thickness planer, you could use it, but that would waste a lot of wood. Instead, re-sawing the board into thinner pieces is the preferred method.
While a band saw is commonly used for this, you can also use your table saw. Ensure the board is properly supported to prevent tipping during the cut. Take your time and don’t rush; safety is paramount when working with large pieces of wood.
Step 5: Cut Notches for the Spine
To enable the covers to fit securely into the spine, you will need to cut notches in the corners of each cover. Utilizing your crosscut sled will provide the precision needed for this cut. Set a stop block to ensure consistent notch depth across all covers.
Once the notches are cut, this will give you a clearer idea of how the box will come together. The back cover will be glued into place, while the front will swing open, allowing easy access to the contents inside.
Final Steps in Assembly
As you begin assembling the box, ensure that the edges are rounded over to create a seamless appearance. This will also help with the functionality of the cover as it swings open. The hinge mechanism will be created using a dowel that connects the spine and cover, allowing for smooth movement.
After ensuring all pieces fit together well, you can glue the inner box to the spine. Be cautious with the glue application to prevent excess from spilling out. Clamping the pieces together while they dry will provide the best bond.
Finally, you will want to add a latch mechanism to keep the box securely closed. Rare earth magnets work excellently for this purpose, providing a clean and hidden solution. Ensure they are properly aligned and held in place with epoxy for a strong hold.
As you progress through the assembly, remember to take your time and enjoy the process. Each step brings you closer to creating a beautiful keepsake box that will be cherished for years to come. Happy woodworking!
Step 6: Create the Hinge Mechanism
As you continue with your book keepsake box, the next crucial step is to create the hinge mechanism. This is essential for allowing the front cover to swing open smoothly. For this project, we’ll be using a simple dowel as the hinge, which will connect the spine and the cover.
Begin by determining where the hinge will be positioned on the spine and cover. Mark the center point on both the cover and the spine. A Brad Point bit is ideal for drilling, as it helps ensure a precise hole. It’s important that the holes are aligned perfectly to facilitate smooth movement.
Drill through the marked points, ensuring you do not go all the way through the spine. This will allow the dowel to act as a pivot point without compromising the structural integrity of the spine. After drilling, insert a dowel, leaving some excess on either side for adjustments.
Step 7: Assemble the Inner Box
With the hinge mechanism in place, it’s time to assemble the inner box. For the inner box, maple is a great choice as it provides a beautiful contrast against the cherry exterior. Start by cutting the maple down to size, ensuring it fits snugly within the spine.
Using a miter sled will help achieve precise mitered joints. If you don’t have a miter sled, a miter saw or miter gauge will also work. Once you have your pieces cut, assemble them using wood glue, ensuring they are square. Clamping the joints will provide a strong bond as the glue dries.
After the glue has set, check the fit of the inner box within the spine. You may need to make minor adjustments to ensure it opens and closes smoothly. A chamfer along the edges can help with clearance, preventing any sticking when the box is in use.
Step 8: Connect the Covers and Spine
Now that the inner box is ready, it’s time to connect the covers to the spine. First, make sure the spine is securely glued to the back cover. This is where you want to ensure everything aligns perfectly before the glue sets.
Once the back cover is glued in place, apply glue to the front cover’s edge, ensuring it aligns with the spine. The hinge dowel will provide the necessary movement, so take extra care to ensure it’s positioned correctly. Use clamps to hold everything in place while the glue dries.
Step 9: Install the Latch Mechanism
To keep your keepsake box securely closed, it’s essential to install a latch mechanism. Rare earth magnets are an excellent choice for a discreet and effective latch. Begin by selecting the appropriate size of magnets, ensuring they provide enough strength to hold the box closed.
Drill shallow holes in the spine and the front cover to accommodate the magnets. It’s important to align them properly to ensure they connect seamlessly when the box is closed. Use epoxy to secure the magnets in place, ensuring they are oriented correctly for a strong bond.
Step 10: Finishing Touches and Final Assembly
With the assembly complete, it’s time to add the finishing touches to your book keepsake box. Start by applying a protective finish. Spray lacquer provides a smooth and durable surface, enhancing the beauty of the cherry wood.
Next, line the inside of the box with felt for a soft touch and added protection for your keepsakes. Use spray adhesive to attach the felt, ensuring it lies flat without wrinkles.
Finally, apply some paste finishing wax to the exterior and the dowel pins to ensure smooth operation. This step will help prevent any squeaking and will keep your box looking beautiful for years to come.
And there you have it! Your unique wooden book keepsake box is now complete. This project not only provides a functional storage solution but also serves as a beautiful piece of art to showcase your woodworking skills.
Be sure to check out Steve’s website for more information: Woodworking for Mere Mortals