This project was built and designed by Connor from Shopfix. Starting with a chunk of maple burl that could’ve easily been firewood, he turns it into a beautifully detailed keepsake box using classic joinery, book-matching techniques, and a clean modern finish.
It’s a great example of how creativity and precision can turn rough, reclaimed lumber into a finished product that feels custom, polished, and high-end. From splines and hidden hinges to a felt-lined interior, every detail in this box contributes to both form and function.
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Rescuing a Piece of Maple Burl
The box begins with a rough piece of maple burl that was picked up for free on Facebook Marketplace. Reclaimed wood like this often has imperfections, but it also offers incredible figure and character that can’t be found in standard boards.
After selecting the best section of the burl, Connor mills it down into thinner strips. This gives him better control during layout and allows him to use book-matching to bring out the grain in a symmetrical, eye-catching way.
Book-Matching for Visual Impact
Book-matching is a technique where two consecutive slices from the same board are opened like a book to mirror the grain. This creates a natural pattern that’s both bold and balanced.
Connor uses this method to showcase the movement and depth in the maple burl. It’s one of the standout features of the final box and a great way to make reclaimed wood shine.
Cutting Grooves and Mitering the Corners
Once the panels are ready, grooves are cut into each piece to accept the top and bottom panels. A dado blade on the table saw makes this efficient, but multiple passes with a standard blade or a router will work too.
The corners are mitered at 45 degrees to allow for a clean, seamless box assembly. Using band clamps keeps everything square while the glue dries, though painter’s tape can also be used in a pinch.
Slicing the Lid Cleanly
After the glue cures, the next step is to separate the lid from the base. This cut needs to be accurate, and Connor emphasizes the importance of making it slowly and with control to avoid any chipping or misalignment.
Cutting the lid free is one of the most delicate moments in the project, but it opens up the opportunity to start working on the box’s interior details.
Reinforcing the Corners with Splines
To strengthen the miter joints, splines are added using a spline jig. Connor chooses mahogany for a sharp contrast against the light maple, turning a functional detail into a bold design element.
The slots are carefully cut into the corners, and the splines are glued in place, then trimmed and sanded flush. This not only adds durability but gives the box a distinct visual edge.
Adding a Border and Building the Interior
Connor installs an interior border to help align the lid and keep it from shifting. This strip sits just inside the box, slightly proud of the base, and fits tightly into a groove in the lid.
He also adds custom interior boxes to organize the space. These smaller compartments are cut with miters and have their own bottom grooves, making the interior just as detailed as the exterior.
Designing the Handle
The handle is shaped from a small block of mahogany and attached to the lid. It’s subtle, comfortable in the hand, and fits the look of the box without being too flashy.
Connor mentions that a metal handle could also work, but for this build, the wood-on-wood combination feels more consistent and high-end.
Installing Hidden Brass Hinges
Hidden brass hinges are used to keep the lid movement clean and the exterior lines uninterrupted. Connor routes shallow recesses to ensure the hinges sit flush and the lid opens smoothly.
These small details go a long way in giving the finished box a professional feel. Proper alignment is key, and careful measuring ensures both hinges operate evenly.
Sanding and Finishing
With all parts assembled, the entire box is sanded smooth. Connor applies a hard wax finish that enhances the color and grain of the burl while protecting it from moisture and wear.
This type of finish leaves a soft, natural sheen without being overly glossy. It brings out the depth in the maple and keeps the look clean and refined.
Final Details and Presentation
To complete the interior, Connor lines it with black felt. This softens the storage area and adds a luxurious contrast to the wood. A small chain is added to prevent the lid from overextending.
These final touches elevate the keepsake box from a simple container to a display-worthy piece. It’s not just a woodworking project—it’s something that feels custom-made and ready to be passed down.
Please support Connor by visiting his website: https://www.shopfix.services/.