The Mrs gave me a box of bowl blanks for Christmas and said "I don't care what else you make, I want you to make me a box"
Hello Bruce.
What size are the bowl blanks and is there a certain size/type/shape of box in mind, maybe a bowl shape with a lid? Loose lid, tight lid? For function or for show? There are lots of options.
End Grain Orientation
Turned boxes are often made with the end grain running parallel to the axis of rotation. End grain boxes will warp less with seasonal changes and the lids often fit better. One part, either lid or base, has a tenon that fits into a parallel mortise on the other part. Turners often make the lids fairly tight so when opening there is a little suction and it makes a quiet “pop” when opened. It's a way to show off skill. However, many people who uses boxes for jewelry, etc, don’t like this since it might need both hands to open. That's the method I learned, but I no longer make boxes that "pop".
Face Grain Orientation
Bowl blanks, on the other hand, usually have the grain going across in "face orientation", grain perpendicular to the axis of lathe rotation. Lidded bowls are boxes, for example “Beads of Courage” boxes are usually lidded bowls, often made in face grain orientation. However, straight sided mortise and tenon fits don't always work well on face grain orientation since the lid can get tight and stick with seasonal changes. I almost always make tapered lids which never stick and can be removed with one hand. I also now make almost every end grain box with tapered lids.
If turning from a typical bowl blank I'd definitely use a tapered lid. It's best if the wood dry. Note that many bowl blanks are NOT completely dry.
I made this visual aid for a Beads of Courage demo to show how a tapered lid can help with the fit. Not only will it prevent sticking, it lets the lid be opened and closed by someone with mobility or coordination limitations.
BTW, for those not familiar with them, Beads of Courage boxes are made for kids, often with cancer, to store strings of beads. They get a colored bead for each procedure, hair loss, etc. Some kids have many hundreds. Turners and woodworkers all over the country make round and non-round boxes for the kids. Many hospitals have a volunteer BOC coordinator who keeps their storage closet stocked. Here's a bit about woodturned BOC boxes:
https://beadsofcourage.org/bead-bowls/
At a turning symposium a few years ago, I examined ten Beads of Courage boxes people donated for the program. The lids on FIVE of them were so stuck they wouldn't open. (I didn't try to use force.) All were made in the face orientation, made like bowls.
Here are a two lidded boxes I made with
tapered fits.
The taper on the lid of this BOC box fits over the rim on the base.
The vessel made in face grain orientation, has fairly large "bowl" made from glued-up 2" thick dry cherry and basswood boards.
This small end grain box has a tapered lid fits down inside a taper on the bottom.
I like the look and feel of this one. (the brass pieces are also turned on the wood lathe)
I made drawings to scale first, then made careful measurements and cardboard templates to get the taper just right.
This is a
more traditional end-grain turned box, not necessarily traditional in the shape but in the way the lid fits.
The lid has an straight-sided mortise which fits over an "almost" straight-sided parallel tenon on the base.
BTW, I sometimes give boxes like this to mothers of baby girls. I figure they might hold diaper pins at first, then the kid might use it for her bug collection, then later for jewelry. Good clean fun!
I learned the basics of box making from Richard Raffan’s books long time ago. He teaches end grain box making.
If you are in a turning club there are usually lots of box-makers who are always willing to help and share techniques.
Some clubs have a mentoring program where you can get one-on-one instruction on sharpening, boxes or anything else.
For a design that makes the boss happy, maybe start by drawing out some shape ideas on paper, and see what strikes the fancy. I almost always do that when I make something. I often make full-sized drawings to avoiding unpleasant surprises and with variations to refine the design. You might even make this a journey, start by some making small boxes (call them prototypes) to refine the techniques, figure out what shapes you and she like best, then work towards a final piece.
If working from bowl blanks you can cut a section off the top to make the lid, but that makes the bottom shorter. An alternative is to cut a piece for the lid off a separate blank or a piece of board, maybe even one with contrasting/complimentary wood.
JKJ
