This project was built and designed by Billy from Newton Makes. It’s a detailed replica of an antique whiskey box, blending traditional joinery with modern techniques to recreate a piece of history in the shop.
The original box, likely made in the 1950s, had been sitting in Billy’s workshop for years—used as storage and admired for its rustic charm. Inspired to remake it, Billy documented the entire process, from studying the original construction to recreating the decorative stamps.
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Studying the Original Box
The first step in the process was closely examining the antique whiskey box. The original bore the stamp “Lord Calvert, Product of America,” along with a coat of arms. While functional, it also held historical significance tied to a Canadian distillery that produced American blend whiskey.
Billy noted the box’s key construction features, including finger joints at the corners and a tongue-and-groove bottom panel. Made from pine, it was both simple and well thought out, with the kind of detail that made it worth preserving—by rebuilding it from scratch.
Recreating Non-Standard Joinery
To start the build, Billy focused on replicating the corner joinery. He designed a jig to cut box joints, thinking it would be a straightforward task. But the joints on the original box weren’t standard sizes, which meant more trial and error than expected.
By using leftover wood from past projects, he was able to refine the jig until it produced joints that matched the antique dimensions. The process required patience, but it paid off in clean, solid corners that honored the original design.
Building the Box Structure
Once the box joints were dialed in, Billy moved on to cutting and shaping the sides. The front panel was intentionally sized to allow room for both the lid and the tongue-and-groove bottom.
The goal was a snug fit without requiring clamping during final assembly. Getting this right was a matter of careful planning and testing—especially since pine can compress easily if overworked.
Crafting the Lid and Tongue-and-Groove Bottom
Next came the lid and bottom. The bottom followed a tongue-and-groove pattern, which Billy recreated using a router. Creating the groove cleanly across multiple boards required steady pressure and consistent cuts.
Once fitted, the tongue locked neatly into the groove, creating a solid and attractive base. The lid was kept simple, sliding into the front face with just enough overhang for grip.
Creating the Decorative Stamps
The original box had stamped markings that added authenticity and character. Billy set out to replicate those using laser-engraved rubber sheets. These sheets were custom-cut to match the design and glued to wooden backers to make usable stamps.
The first few tries revealed a problem: ink bleeding into the wood grain. After experimenting, Billy found success by first stamping onto a scrap board, then applying that inked rubber to the finished box. This technique gave cleaner lines without blotching.
Adding a Functional Notch
As a final design touch, Billy added a small triangular notch to the lid. This was inspired by the original and provides a simple way to lift the lid without needing a handle.
It’s a small feature, but it adds to the overall usability of the box. It also shows how traditional designs often include smart, subtle details that are easy to overlook.
Assembling and Final Details
Once all the components were ready, the box came together quickly. Billy took extra care during assembly to maintain square corners and minimize gaps.
The fit and finish of the replica were impressive—tight joints, clean lines, and just enough age-worn character to pay homage to the original. The end result felt authentic, but clearly updated with cleaner craftsmanship and a refined process.
Reflections on the Build
This project served as more than just a woodworking task—it was an exploration of the past through making. From the challenge of non-standard joinery to the creativity of replicating old stamps, the build pushed Billy’s skills and rewarded his patience.
Along the way, the project became a reminder of what makes woodworking enjoyable: solving problems, improving your process, and ending up with something unique and lasting.
A Project Worth Revisiting
By the end, Billy had recreated a beautiful whiskey box that captured the spirit of the original. It wasn’t about copying every detail—it was about understanding why the original worked and bringing that same care into a modern build.
For woodworkers looking to mix function, storytelling, and traditional joinery, this project offers a lot of inspiration. It’s proof that old designs still have plenty to teach.
Please support Billy by visiting his website here: https://www.newtonmakes.com/shop.