As I explained in a previous post, I received a commission for a tea box in July. As part of the build, I wanted to create a full sized “mock up” of the tea box. The purpose was to work out the dimensions and joinery of the box, as well as to provide the customer with a sample version. This would enable the customer to test it out and provide feedback.
I used inexpensive pine to create the mock up, with some small walnut stripes. The actual build will consist of walnut sides with maple stripes – so the mock up is almost 180-degrees different from that in terms of appearance. Still, I think it’s a very valuable process in order to ensure the customer gets what they want.
To start, I ripped boards to the width (the stripes are ½” wide) with the sides slightly wider than necessary. I then glued these up to be used for the top, front and drawer front pieces, with a little leftover.
From there, I used the tablesaw, router plane and chisels to cut out the dados, grooves and rabbets for the joinery. The side pieces have rabbets in the back, top and bottom, and a stopped dado in the front for the front panel. The back and front panels have a rabbet for the top piece, and the bottom has a rabbet for the back panel. All four of these have a groove for the inner panel, which separates the drawer from the top compartment. A lot of cuts!
The drawers have a simple groove on all four pieces for the bottom, and dados on the front and back to hold the side pieces in.
With all the joinery done, I did a dry fit, and then glued and clamped them up. I measured the diagonals to ensure the case was being glued up straight and square.
After that, I sawed off the top 1” of the case for the lid, and then used chisels and my small router plane to cut in and install the hinges. These are brusso 95-degree hinges, so they’ll open a little past 90 degrees and stay open
The last step was to drill in for the front knob on the drawer. Note that the drawer has dividers in it, to keep the tea bags separated.
I put on one coat of laquer to seal it, since its just a mock up.
Took to the customer on Friday, and they are reviewing it in order to provide feedback. They already said they would like the drawer to be about ½” taller. The upper compartment is good, so the whole box will need to be ½” taller.
Kevin