Geoff Birtles, Templestowe, VIC

Document & Memorabilia Box
Blackwood, Tasmanian myrtle burl, Huon pine
320 W x 238 D x 67mm H, Carcase 9.2mm D

Concept
An elegant coffee-table box with presence. Restrained, simple lines, not overpowering in size.
This required more compact dimensions than a regular document box. The box holds around 100 A4 sheets under the tray, and about the same again in A5 sheets on the LHS of the top tray. The RHS is for pens and memorabilia. (In practice, the entire box is used for sentimental bits and pieces in memory of my late wife).
Design
i. General
My inspiration to ‘pick up the tools’ is either a utilitarian/creative need or inspiration from the wood itself. In this case they came together. I needed a memorabilia box and I had just returned from Tasmania very keen to build a project from all Tasmanian woods. In particular, I wanted to explore the potential of some of the beautiful veneers I had acquired there.
The carcase is nicely figured blackwood (which flows around the box), the lid insert Tasmanian myrtle burl veneered to 6mm MDF, surrounded by Huon pine filets. The tray is all Huon pine and the box base Huon pine veneered to 3mm MDF. Each wood harmonizes with the other to provide a nice Tasmanian ‘provenance’.
ii. Lid
Generous mitred frames are intended to draw the eye into the myrtle burl insert (picture frame effect). I wanted this striking first impression (which after all, does create a visual destiny and expectation) to continue when the lid is opened. I achieved this by veneering both sides of the MDF lid insert with the myrtle burl and ‘resting’ it on rebated inside frame edges. These provided a 4mm shadow line around the inside burl—a nice and involving visual progression from the top of the lid.
iii. Tray
The lift out Huon pine tray sits closely to all four inside carcase sides to create an impression that the inside of the box is lined (with Huon). The tray’s burgundy felt bottom lining and box’s brass fittings help deliver on the visual expectation created by the outside top of lid and accentuates the heirloom feel of the piece.
iv. Mechanical
Dovetail joinery, two small piano hinges and a simple polished solid brass catch provide complementary but not obtrusive details and an enduring construction.
Materials
Solid wood for carcase and tray sides (Tasmanian blackwood and Huon pine), myrtle burl veneer for lid, MDF substrate for veneer work (bottom of box and tray), brass fittings with traditional brass screws.
Glues
Titebond 3 PVA for carcase, lid and veneering (I found out the hard way that this discolours glue lines on blackwood, much angst, but resolved!), Mitre Pro Rapid Set epoxy for insert tray.
Method of Construction
All milling and sizing from rough lumber in my workshop.
Power tools included: bandsaw, jointer, thicknesser, drum sander, tablesaw, router-table.
i. Carcase
Machine all four sides to thickness, length and width being very careful about tearing and burning (Tasmanian blackwood!). Groove inside front and back for tray supports. Assemble frame with dovetail joinery (Gifkins Jig). Inside bottom edge rebated with a pattern following router bit after assembly and squared by hand chisel. Huon pine veneered to 3mm MDF, fitted to inside bottom dimension and glued.
ii. Lid
Frame cut to oversize width and length for all four sides, inside edges rebated, 2mm thick Huon pine filets glued in place, then front, back and sides 45° mitre cut to length. PVA glue and hidden splines used for frame assembly.
Myrtle burl dampened and flattened with newspaper, melamine cauls and SCUBA weights. Veneered to both sides of 6mm MDF with yellow PVA using melamine cauls and lots of clamps.
Lid insert cut fractionally oversize, then ‘nibble fitted’ to sit on inside frame rebates, level with top of box. This left a 3mm shadow line around burl inside the box lid.
Complete lid glued to carcase top, reinforced and positioned with splines.
iii. Preliminary Finishing
Some preliminary finishing work to outside of intact carcase and lid. Flush finishing of glued lid to carcase sides, and leveling of Huon filets by scraper and sanding. Dovetails trimmed back flush with hand chisel. Preliminary sanding of all with 180 grit. Some careful random orbital sanding of lid, the rest by hand.
Lid (incorporating some 9mm of carcase) cut off on tablesaw using rip fence and fine kerf blade. Minor inside glue clean up and sanding.
iv. Fit lid and hardware
Used shop jigs and router table to fit two small piano hinges. (Piano style for large lid stability, two small hinges to lessen the impact of brass and keep the eye on the wood). Ensure lid and carcase flush on all four sides, and correct hinge clearance. Fitted brass front catch.
v. Tray
Half lap corners with frame sitting on Huon/MDF bottom. All glued with epoxy. Note finger detail on divider.
Finishing
• Disassembly
• Sanding 180, 220 and 320 grit papers, then #0000 steel wool. HP blow off between grits and on completion of sanding.
• Spray, two coats (wet on wet) of Mirotone Mirobuild AC362 two pack clear acid catalysed sealer.
• Hand sand with #320 grit aluminium oxide paper (white).
• Light burnish with #0000 steel wool.
• Wax with Mirotone Mirowax 738. Wipe excess off after a couple of hours.
• Allow 24 hours to harden.
• Re-assemble box, light final wax.
• Buff after a few days.
This combination of two pack sealer and wax provides a hard durable finish, that is luxurious to look at and silky smooth to touch.

Photos: Geoff Birtles