This keepsake box was created and designed by Steve Ramsey from Woodworking for Mere Mortals. Using salvaged pallet wood, Steve walks us through the steps to make a beautiful box that is perfect for storing cherished items.
Materials Needed:
- Pallet wood
- Wood glue
- Clamps (pipe clamps or parallel clamps)
- Sandpaper (60 grit and 150 grit)
- Router with a quarter inch straight bit
- Table saw
- Disc sander
- Black felt (for lining the box)
- Double-sided carpet tape
- Sacrificial boards
Tools Required:
- Table saw
- Router table
- Random orbit sander
- Cross-cut sled
- Digital angle finder
- Rubber bands (for dry assembly)
Step 1: Prepare the Pallet Wood
Steve starts by dismantling an old pallet to salvage the wood. He mills it down to 1.5 inches wide and 0.25 inches thick for his small projects.
Step 2: Edge Join the Boards
To create a wider board for the box, he edge joins two pieces at a time. He carefully matches the grain to ensure a seamless flow.
Step 3: Clamping the Panels
Using pipe clamps, Steve applies a thin bead of wood glue along the edges and spreads it evenly. He checks for flatness with a square and adjusts the clamps as necessary.
Step 4: Sanding the Panels
After allowing the glue to dry, he sands the panels with 60 grit sandpaper using a random orbit sander to remove excess glue and smooth out any imperfections.
Step 5: Cutting to Size
Next, Steve determines the size for the box and begins ripping the boards down to size, ensuring the seam is centered for a polished look.
Step 6: Making Rabbets
He sets up the table saw to cut shallow rabbets on the edges of the boards, which will hold the top and bottom panels of the box securely.
Step 7: Routing a Groove
Using a router, he cuts a groove to create a shallow lid. This groove will allow the lid to fit snugly onto the box.
Step 8: Cutting the Box Sides
With the cross-cut sled, Steve cuts the sides of the box at a 45-degree angle, ensuring all pieces fit together perfectly.
Step 9: Dry Assembly
He dry assembles the box using rubber bands to hold the pieces together while he cuts out the top and bottom panels to fit perfectly.
Step 10: Gluing the Box
Steve glues all sides of the box together at once, ensuring everything is square and aligned. He removes excess glue before it dries.
Step 11: Final Sanding
After the glue has dried, he uses a disc sander for precise finishing, ensuring the edges are crisp and clean.
Step 12: Adding the Finish
Steve applies a few coats of spray lacquer for a durable, beautiful finish that enhances the wood’s natural beauty.
Step 13: Lining the Box
To complete the project, he lines the inside of the box with black felt using double-sided carpet tape for a refined look.
Conclusion
This simple, yet elegant keepsake box highlights the beauty of pallet wood and showcases Steve’s woodworking skills. It serves as a reminder that simplicity in design can lead to stunning results.
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