Tuesday, February 18, 2014

P.O. Box Banks

I bought the Post Office box doors on eBay about 5 years ago.  I began to make wooden boxes for them, but they were coming out so lousy that I put the doors away and tossed the boxes.  But, after making the keepsake box with all the finger joints, I was motivated to try again.
Here are the doors:
I cleaned them up a bit, I thought they were brass, but looking at some areas on the inside that were untarnished shows that they're copper, and if I got some really strong cleaner, I could have them shining like new pennies.  But I didn't want that, so I cleaned them but left the patina.

I cut the finger joints using the router table:

I stacked four pieces, which raises the risk. A mistake will ruin them all at once!

Joints cut:

It takes some fussing and trimming to get them to actually go together:

Then there is the rounding and sanding:

Then a slot is cut to fit in the back piece:

I also made the base pieces, and did some sanding and staining:

After gluing the pieces together, I glued in spacers that will actually hold the doors.

I also cut and sanded all the ebony pegs I needed, and set them in.



The base is screwed on:
                                            

The spacers have to be adjusted to accommodate the doors, they are not really square.

I made some coin-slots out of ebony, and set them into the top.

To get the recess the correct depth, and flat on the bottom, I used my Stanley 271 mini-router plane which I picked up that very morning at the old-tool swap meet.

Then I sanded the ebony piece and glued it in:

Then I screwed in the doors, which is kind of a hassle because there isn't enough room to fit in a drill or screwdriver.  But somehow it gets done.

I took some glamour shots: