Ray Brien, Invermay, TAS

Leaf Box
Tasmanian blackwood
280 L x 65 D x 70mm W

Concept:
The concept arose from the need to develop an item to be displayed at a craft exhibition. Part of the brief was to explore and develop different takes on everyday objects. I was taken by a number of books on band-sawn boxes, but wanted to have something other than a slide out drawer. The shape is derived from the shape of juvenile eucalyptus. I also wished to reduce the amount of waste in the building of this box, which led to the incorporation of the interior lift out drawer made from the centre cut out section.
Materials:
These two boxes are made in Tasmanian blackwood. The pieces were scrap left over from other unrelated projects. The interior is finished with black flocking powder.
Method of Construction:
The boxes are roughed out using a bandsaw to the overall leaf shape from dressed timber, and then a slice (approx 10mm) is removed from top and bottom. The resulting centre section has the centre cut out marked out; large diameter holes (25mm) are drilled at each end of the section to be cut out. The piece is then returned to the band saw and starting the cut near the tip of the leaf, the cut is continued parallel to the edge to join up with the drilled holes. The resulting cut out centre section is retained to be used as the lift out drawer. The saw cut in the centre section is glued closed at this time. Once the glue has cured, the interior surface is sanded on a bobbin sander.
The box is ready for initial glue up. The slice previously removed as the bottom is glued to the centre section. Once the glue has cured, the top slice is reattached with double-sided tape and the exterior of the box is carved and finished to final shape. The top slice is then carefully removed and set aside.
The cut out centre section is cut to half height; a thin slice is cut off and retained. The interior of this piece is removed with a scroll saw to form the lift out drawer. The inside is sanded smooth and the bottom slice reattached. The exterior is then sanded to required finish. Small pieces of 10mm dowel (cut in half lengthwise) are cut to the required length (measured off job) to support the drawer insert and are glued to the finished box.
A selected piece is shaped by hand to form the spine of the box and then glued to the top. The top is then distressed with a rotary burr to give the desired finish.
A 6mm hole is drilled in the centre section for the pivot axle. The hole is approximately 19mm deep. A shop made centre marker is inserted in the hole to mark the position of a corresponding hole in the lid. he 6mm hole in the lid goes just through the lid into the spline. piece of 6mm brass rod is cut to length (25mm) and epoxied into the lid hole. The exterior of the box has desired finish applied and the interior finish applied.
Glues:
Exterior grade PVC, Five-minute epoxy.
Finish:
Exterior finish – Organoil hard finishing buffing oil – three coats, last coat wet sanded with 600 grade wet and dry paper. The unit is then buffed with a lambs wool buff until the desired gloss is achieved.
Interior – Black flocking

Photos: Ray Brien