BoxHeads.net – The Story
Hi my name is Ash, a.k.a. BoxHead, maker of beautiful boxes.
Wikipedia defines Maker culture as a technology extension of the traditional arts and craft movement. Makers typically utilise existing high tech in new and innovative ways. Diverse skills such as metalworking, woodworking and robotics are acquired and then applied.
Until now my life has been one of movement.
My passion for the ocean has been satisfied through many thousands of sailing miles both racing and cruising including the notorious 1998 Sydney to Hobart. The brooding beauty of Bass Strait, it’s islands and nature have left a permanent imprint on me.
From vessels to vehicles. I spent almost 40 years in the road transport industry. From operating the largest of trucks, 50 meters long and 110 tonnes; to supervision, ITS and management. Road transport was very good to me though if I ever see the inside of another lorry it will be too soon.
After sailing around Australia, I ran aground in Perth, WA. There was purpose in the move ashore. The Maker ‘itch’ needed to be scratched. In hindsight, scratched was an understatement. With the router built, the worlds of Computer Aided Design (CAD) and Computer Aided Manufacture (CAM) needed to be explored. They are worlds where creativity and imagination are the only limiting factors.
We live in a world where sustainability is no longer optional. I intend BoxHeads to have the smallest footprint possible. By using wood as the primary material BoxHeads is carbon negative.
BoxHeads.net – The Process
The classic ‘box joint’ method of construction is utilised where possible. The method causes items to align squarely during assembly as well as providing greater surface contact for adhesives. This means no mechanical fasteners are required.
To streamline the drawing process a program was written to automate the task. The entry of size, joint pitch etc produces a CAD file that can include features such as handles. All parameters are configurable including many features that simplify the subsequent machining tasks.
Selection of suitable, sustainably sourced plantation plywood is critical. In particular, I love using Queensland grown Hoop Pine.
Most makers fail at the point where the box needs to be assembled. Ideally each side of the box will need to be clamped in two perpendicular direction simultaneously. Proprietary methods have been developed to solve this. The pitch of a box joint will change given an item’s dimensions. This means clamps used on one item may not be suitable for another. ‘BoxJaw’ is a clamping system that has been developed in-house. The solution allows for each joint on all planes to be securely clamped at the same time. There are two versions of the system. BoxJaw 2.2 can be reconfigured into any joint pitch and is mainly used for low volume work. BoxJaw 3.0 is made specifically for an item. It’s components can be drawn and machined with the item itself. BoxJaw 3.0 is typically used for high volume work. Both types of clamps can be reused on many items.
Boxes are finished using a hand held router with a modified base plate. A large linisher sander rapidly levels the joints and random orbital sanding down to 240 grit obtain a surface ready for coating.
Depending on the predicted severity of an item’s use, an epoxy fillet is applied to inside corners. This is a boat building technique when used, the wood should fail before the joint does, ensuring reliable performance and safety for the user.
As a natural product, wood, if not cared for correctly will break down and decompose. BoxHeads.net.au offer a range of coatings to help prevent this. The most simple and natural is linseed oil. Where an item will spend time in direct sunlight and the weather more generally a water based acrylic polyurethane is recommended.