On this instructable, im going to explain to you how i made the reprodution of thi box possible.
Step 1: Create Plans From the Original Box
Before explaination , let's talk about this box :
This box was sold in a auction house in france last year and we found it's image on the web.
The commisaire in charge estimated the box from the XIII th century but the lock is from the XVI th century, at some point , it must have been changed.
The particularity of this box it's that the head is made in one piece of wood
Dimensions from the original :L 32cm x l 23cm x H 21cm
Now , with all of theses elements, i did the plans and lets go for step 2
Step 2: The Head of the Box
So, the original was made in chestnut, but in France today, it's simply impossible to find a piece of chestnut that size, so the idea was to use elm .
This kind of work can only be made by hand:
first step using scisels is to cut out the inside of the head , clean it and sand it.
second step, using hand saw, the outer part of the head was cut.
Step 3: Assembling the Box Itself
Now that's the easiest , assembling the box and the head.
step one: cut the board and give them the right angle .
step two: glue all together with wood glue and the box is done
sanding and finishing
Step 4: Dyeing Step
Now it's dyeing time, looking back at the original, the idea is to use tincture, with different try and mix, to approach the color of the original box
Step 5: Creating Templates for the Metals Parts
The idea is to glue the the part of the plans wich corespond with metal part on cardboard (cereal boxes for exemple )
and then once i got the templates, i put it on the metal plaques and spray paint it.
Thickness : 1.5 milimeters
Now start the longest work.....
Step 6: Making Angle Irons and Hinges
after cuting all parts with the metal hand saw ( jewlery hand saw ), all the paterns where made using metal file ( needle file )
and believe me , it take time !!!!!!!
Step 7: Bending All Metal Parts
for this step what you need to know :
In order to have the iron angles at the proper angle , you need to bend it and then re-open it, for that the parts must be heated at each step of the bending.
Step 8: Finishing Hinges, Lock and the Box Handle
All the photos are in the right order, sorry
the handle : after drawing a template or patern , the handle was bend and forge then monted on the iron angle
The lock: actually it's a lock without mecanism for the moment, but it come one day.
all the metal parts were cleaned with metal whool and polish with bee wax
the hinges: bend and monted together
Step 9: Assembling
Now evrerything is done, it's time for assembling
Every metal parts has been mouted with nails, wich have a head like a half ball ( dont know it's name in english )
The box is protected by a plastic film, the same that we have in our kitchen.
The metal parts can be placed at there right place and marked before nailing
Step 10: Box Finished
For making this box i used :
A plan from : leplanhisto.com
Big piece of Elm
Spare parts of metals
Wood work: 16 hours
Metal work: 30 hours
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