Welcome back Mike.
Shaker boxes are right in my wheelhouse at the moment.
I also took a class from Ralph some 10 years ago in Chicago in
conjunction with a MWTCA regional meet. In addition, I stay in touch
with John Wilson and Eric Pintar at www.shakerovalbox.com in downstate
Charlotte, and visit them whenever I pass through there.
I’m making up a large batch of boxes and trays right now for an art fair
this weekend. So with the volume of pieces I make, the process is not
entirely unplugged. My methods are a blend of those two influences. I
sometimes taper the fingers a little bit, but I always taper the buried
ends to a feather edge, and use a #3 or #4 bench plane. I clamp the
veneer strip to the bench on the back end, and set the front of the
strip right up to the edge of the bench. I plane the last ~2” (usually)
tapered down to transparency. Sometimes they are a little ragged, but
they are naturally held against the inside of the box. If it looks too
ratty, I just slice off a diagonal once it is assembled and it looks
fine. For box sizes 1 – 3, I start with ~.065 to .085 red maple veneer
that a local mill cuts for me. I can get 1/16” on my band saw too, but
it’s kind of a bother to make a lot of strips 15” to 48” long with any
consistency. For cost reasons, I do slice my own birdseye veneers ~.050
- .070 for gluing to ¼” birch plywood for the tops.
Merry Christmas and best wishes to all,
Jim O'Brien
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