This instructable defines step by step how to make and assemble this FlatPack Jewelry Holder. Please follow these instructions accurately.
Step 1: What Do You Need?
MATERIALS and TOOLS
1-11: displayed on the picture above; you need a pencil as well.
13: drill press or drilling machine
14: belt saw
15: sanding machine
Step 2: How to Make a Flatpack Jewelry Holder
Open the pdf-file W6 instructable to see the steps in a better way.
Laser cutting process
1. Take two birch plates of 450 by 600 mm, with a plate thickness of 3 mm each.
Open the pdf-files "Lasercut juwelenhouder_v2 and Dekseltjes" and "Lasercut juwelenhouder_v2". Start the laser cutting process.
2. The cutting process results in a large amount of equilateral wooden triangles and two circular finishing covers: a large finishing top cover (1) and a slightly smaller cover (2).
Finishing of the wooden triangles and felt
3. Prepare a wooden beam of 550mm (length) x 34mm (height) x 34mm (width). Fix the beam in the bench as shown in image 3. The width of the beam should equal the height of the wooden triangles.
4. If necessary, adjust the beam to the height of the triangles (i.e. with a sanding machine). Fix the beam between the upper and lower part of the bench, in a countersunk position of 1 to 2 mm.
5-6. Position the triangles side by side on the beam, as shown in images 5 and 6. Check the positioning of the triangles: they should slightly rise above the upper and lower part of the bench.
7-8-9. Fix a sheet of fine sandpaper on the sanding machine.
10. Sandpaper one side of the triangles slightly to obtain the natural birch color.
11. Remove dust by using a soft brush.
12. Collect the triangles with the sanded side up.
13. Take a sheet of felt of 420 mm by 560 mm; adjust dimensions by using a box cutter.
14-15. Verify the dimensions of the piece of felt, and adjust if appropriate.
16-19. These steps are part of the learning process. Skip these steps. They include additional performations in wooden parts. These perforations haven been integrated in the update version of the cutting process file.
20. Position the triangles as shown in image 20. Continue the procedure along with the glueing process described in steps 21-22..
21-22. Glue the triangles together on the piece fo felt. Apply the glue on the non-sanded side. The distance between the rows of triangles should be 3 mm. Verify these dimensions carefully.
Production of the bottom and top MDF circular plate.
23. Mount the wooden frame of the jewel holder. Take a MDF-plate with a thickness of 12mm. Draw two squares of 128 mm x 128 mm.
24-25. Draw the diagonals into the squares. In addition, draw a circle with a radius of 64mm in the middle of the square and mark the tangent lines on the diagonal lines. Draw a polgon by connecting the marks. Image 25 shows the result of this process step.
26-27. Cut out the polygons as shown on the image.
28-29. Sand the polygons with an appropriate sanding machine in order to obtain two perfect circles. These are the top and bottom MDF circular plates of the jewelry holder.
Finishing of the top and bottom MDF circular plates
30-31. Make a mark on the side of the top MDF circular plate (=plate A). Take a flexible meter and make a second mark at 37 mm of the first mark. Continue this process along the entire outine of the top cover. Repeat this process on the bottom MDF circle (=plate B).
32. Draw straight lines through the marks on the side of plates A and B as shown on picture 32.
33-34. Plate A: mark the middle of the top cover; use subsequently a pencil and an awl.
Plate B: make a mark at 5 mm from the bottom side of the plate; use subsequently a pencil and an awl.
35. Drill holes in the side marks with an appropriate machine (fraise, drill). The specifications of the holes are the following: depth 20 mm; diameter 5 mm.
36-37. Make out of a 6 mm diameter wooden rod a set of rods with a length of 35 mm. The total amount of rods needed is 75.
38-39. Bottom side of plate A: draw with a pencil an equilateral triangle of 110 mm; make a mark at 15mm of all angles of the triangle. Connect the paired marks at each angle in order to determine the middle point of each angle; put a mark at the middle points of each angle with an awl.
Repeat this process on the top side of plate B.
40-45. These steps are part of the learning process. They are identical as step 35. The pictures show the process of drilling process of plate B. They are shown for information purpose only.
Finishing of the felt sleeve
46. The wooden triangles have been glued on the felt. During the lasercutting process, each triangle has got a hole in the centre. Use a drill to make wholes in the felt.
47. Take a piece of felt of 36 mm by 42 mm; glue this part in order to obtain a cilindrical sleeve.
(This step is part of the learning process; in routine manufacturing, the felt for the jewelry holder should be just one piece with the appropriate dimensions)
48. Finish the sleeve by glueing a set of triangles on this uncovered strip of felt. Follow the instructions as described in steps 21-22.
49-50. Top side of plate A: attach the cover (2) obtained in step 2 with the top side of plate A with an appropriate wood glue.
Proceed with the assembly of the FlatPack Jewelry Holder following the instructions below.
Step 3: Assembly Instructions for the Jewelry Holder
- Place the bottom-cover on the table. Be sure the holes are visible from above.
- Press the long wooden rods in the holes.
- Place the top-cover on the wooden rods.
- Slide the sleeve over the construction.
- Attach the cover to the construction. The lower and upper row must be fixed with the small rods. Place at random some small rods on the sleeve. Both the felt and the rods can be used to attach your jewels.
Step 4: FlatPack Jewelry Holder Exploded View
The exploded view of the FlatPack Jewelry Holder shows the order of assembly of various parts.
Step 5: Use of the FlatPack Jewelry Holder
The picture above shows how to use the top-cover of the FlatPack Jewelry Holder.
Step 6: The Jewelry Holder As a FlatPack.
When folded as shown above, the Jewelry Holder can be packed in a flat cardboard box. This flatpack format enables a simple and economic transportation.