Boxes: Lessons Learned & What the heck is taking so long.
I am a lousy estimator of the time it takes to make 40 wooden boxes. This much is apparent by now.
Those of you waiting for a wood box are surely aware that your reward has not yet arrived on your doorstep yet, as promised by my last post.
Here's where I went wrong: I missed the part where cutting the miters for the corners inevitably results in some amount of tearing out, or places where the grain of the wood is broken away by the router bit as it spins across the end grain of the wood.
Not a big deal, as it can be patched and corrected. But, like every other part of this process, it takes time & care. Filling gaps with wood putty (after matching colors) and then refinishing the patched areas with the same 6 layers of shellac and polyurethane as the rest of the box with a tiny paintbrush, while sanding between each layer, takes a considerable amount of time and care.
Anyway, just to show that we aren't scamming you, here's what the workbench looks like tonight:
As you can see, we've made it to the "cutting the lids off" phase. They're not fully cut off yet. There's 1/32 of an inch of material still connecting the lid to the box. Why? To avoid taking any damage from the table saw, the cut is made to within 1/32" of cutting all the way through the wall. The lids will be finally separated with a utility knife and a hand plane will be used to clean it up.
Here's a photo that shows off the logo on the box:
And here's an inside shot of what it looks like with the lid cut off and the insert placed inside:
While this is happening, Dad is building the jig to mortise out a recess in both the box and the lid for the hinge. Another step where great care and precision is necessary, but once the jig is built, the actually cutting goes pretty quickly.
Once the mortises are all cut, then the recently exposed edges go back for finishing. Again, this will be done by hand and will take a number of days that is hard to determine exactly.
Now the good news! Once these edges have the finish applied and re-sanded, the rest is an assembly line process. Hinges, latches, and inserts will be installed, and the inner label will be pasted on and autographed, and then we package and ship!
So when is this going to happen? At this point, I am reluctant to give you a date, for fear of giving you another missed deadline. I think it's incredibly safe to say that everyone should have their boxes in time for Christmas. Keep in mind, that's an intentionally well-padded estimate, and there is every indication that we'll be done well in advance of that.
Rest assured, though, that daily progress is being made.
I'm happy to answer any question you may have. Feel free to send me a message through Kickstarter or email me directly at firstname.lastname@example.org