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<\/figure>\n\n\n\nBoxHeads.net – The Process<\/h1>\n\n\n\n
The classic \u2018box joint\u2019 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.<\/p>\n\n\n\n
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.<\/p>\n\n\n\n
Selection of suitable, sustainably sourced plantation plywood is critical. In particular, I love using Queensland grown Hoop Pine.<\/p>\n\n\n\n
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\u2019s dimensions. This means clamps used on one item may not be suitable for another. \u2018BoxJaw\u2019 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\u2019s 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.<\/p>\n\n\n\n
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.<\/p>\n\n\n\n
Depending on the predicted severity of an item\u2019s 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.<\/p>\n\n\n\n
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.<\/p>\n\n\n","protected":false},"excerpt":{"rendered":"
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 … <\/p>\n