Repurposed Pen Box

I was making a box to store some lighting-related stuff. The idea was to cut foam inlays for the box to hold the bits. I was actually working on this box concurrently with my recent gaming accessory box, and so it was part of the same batch of experiments (such as using the same batch of resin for the inlay). However I somehow made a mistake when programming the G-code and only made it 3cm deep instead of the intended 5cm deep, and I didn't even realise it until I was cutting the foam. So I decided to use it to store some of my nicer pens that don't have their own proper box instead.

From left: Noodler's Konrad Dixie No. 10 Methuselah, FPR Himalaya green ebonite, FPR Himalaya amethyst purple acrylic, Parker 51, Omas 361, Pilot Elite, Lamy Scribble, Aurora 98 Archivi Storici, Rotring Esprit retractable graphite, Pilot Decimo dark grey.

I was using the leftover 20mm foam from when I made a foam insert for a statue. I thought it would be cool to have a protective piece of foam actually attached to the lid rather than have one sit on top of the contents, so I inlet a large pocket inside the lid. Unfortunately the plywood I was using was just over 5mm thick, and with the resin inlay on the outside I was afraid to cut out too much incase the lid became too flimsy, so I only cut the pocket for the foam to a little under 3mm deep. Which is quite thin, but still probably enough foam to protect the contents?

I glued in a sheet of foam, and then trimmed it flush on my hot wire cutter.

Since the box interior was 30mm deep and I was using 20mm thick foam, I had to actually slice one piece in half, down to around 10mm thick, to make up the 30mm thickness. This would be the bottom piece. I did this by sandwitching it between two pieces of wood, marking the line I wanted to cut, standing the wood-foam-wood sandwitch on it's side, and carefully running it along the fence on the hot wire table while trying to keep it upright so the wire would cut a consistent thickness.

I found that the foam insert in the lid actually catches slightly on the foam inside the box, creating resistance to closing. In fact the lid tends to "bounce back" after closing, leaving it open by a few mm. It can be rather hard to get it to fully close. Initially this was MUCH worse; it was hard to close at all and impossible to get it to stay completely closed. But I cut the inner piece of foam a bit lower and now it's much better, but still annoying. I'm not sure what the best solution is, perhaps I can find a way to cut the lid insert to be slightly thinner than the recess, or I just need to cut the body inserts to a bit lower.

I printed a template for the cutouts for the main piece of foam. I cut the inner pieces out of the template, then pinned the template to the foam with tailor pins.

I then cut out the pieces of foam on my wire cutter. This was a little fiddly as I had left very little material for the walls, so the whole block lost it's structural strength very quickly, making it harder to manouver across the wire cutting table.

I probably got too greedy and tried to fit in too many pens. The wood is also probably too thin, and annoyingly the lid is slightly bowed out - I really want to use solid, stabilized wood in the future, but that's a lot of work and I'm not really set up to process wood properly. Well, overall this box came out OK and it's nice to have a better storage solution for some of my pens.

Improved Game Accessory Box

My last attempt at a gaming accessory box for Warmachine worked fine for the cards, but it was very inconvenient when it came to the gaming tokens - at least in the amount that I carry around for Warmachine. After checking my carrier box I decided I had room to make a larger version that could organize everything better. I couldn't increase the height if I wanted it to fit in my case, but I could increase the width and depth. So I designed a new double-sided box; this would allow me to store cards on one side yet still have a large, shallow area for storing and organizing tokens on the other.

On one side I have enough room to store 3" cloud templates (up to five of the acrylic ones I'm using; I don't think WMH uses the larger 4" and 5" templates anymore) and still have several compartments left over in my 3D-printed divider for dice, tokens, pens, etc. I think I could even fit a small measuring tape in the middle, if I could find a good one. The other side has four compartments, each large enough for around fifty game cards in Dragonshield sleeves. Of course they can also be used for more tokens if needed.

This box took me longer to make than I had hoped. Double-sided boxes are something I've been having trouble getting dialed in, likewise partitions have been proving tricky. My first attempt actually didn't quite go together right, and the box glued up wonky. So I went back and modified my code, double-checking pretty much every aspect of the sizing and tolerances. I also changed my workflow to focus on accuracy (at the cost of a great deal of speed; this box took many hours to mill).

Previously I've been using a 3mm compression bit, and cutting through the entire stock in one pass. This is very fast, but I was getting some deflection. So this time I tried a 1.5mm bit (single-flute upcut as that's what I had) and used multiple very shallow passes; this gave me much better dimensional accuracy (and also meant I could use dogbones without them being nearly as noticeable), but took much, much longer. I also broke the 1.5mm bit, but that turned out to be because a connector for my spindle power cable was crap; it's only a few years old but the plastic had become brittle and the retaining tabs had snapped off. I noticed this and taped the connector ends together, but the tape apparently decided it couldn't be bothered to do its job and just kind peeled off partway through a cut, allowing the cable connector parts to separate and leaving the machine trying to drag a non-spinning bit through the plywood.

Speaking of plywood, I'm not too happy with the quality of what I'm using right now. Lots of voids in the middle, and it all splinters very easily, the box finish getting damaged during assembly and sanding (in a way that feels like it shouldn't be happening). This was especially true of the box lid "runners", the tongues and grooves that hold the box lids in place. So to try to reinforce them, I added varnish first, before sanding to fit. I actually tried to apply the varnish and then put them in a vacuum pot to draw the varnish deeper into the wood, but I don't think that really did anything. Regardless, I think the varnish helped to reduce the damage to the tongues and grooves when making the second box.

I wasn't too happy with some of my other materials either. My old wood glue had turned weird and yellow, so I threw it out and bought some new wood glue from the local hardware store, but this stuff... feels different. It's labelled HP Gold Synthetic Resin Adhesive, and it doesn't feel like the PVA wood glues I'm used to; it doesn't spread very well for example, and I feel like it might be setting more quickly. It worked, but the difficulty I was having spreading it might have been compounding the issues I've been having with box glue-up.

You see, applying glue to the correct places on all the sides and partitions was taking so long that the glue would start to harden before I was done, and pieces would end up setting slightly out of place. So for my second attempt at this box I tried applying glue to just two pieces at a time, then quickly assembling the box parts and applying pressure so that the two pieces would set in the correct positions. Once they were set I would take everything apart, apply glue to two more pieces, and repeat the process. This again took a long time, but I feel it worked better. I do need a better clamping solution though; my clamps are too big, elastic bands actually work better than clamps for smaller boxes but the ones I have are too small for this box.

I did think the resin inlays worked much better this time than in my last attempts. I started by applying a very generous coating of Coprabel's Easy Color wood stain varnish in Palissander 506 into the inlay to seal the wood. It's the varnish I used for the finish on my previous game box; I hoped the very dark colour would create a sort of blackline around the actual resin. After giving this a day to set, I applied a clear varnish (National Protective Coatings synthetic varnish clear) to the entire top of the lid. This was to avoid the issue I had with the previous box, where sanding the resin inlay flat created a coloured dust that settled into the wood top and refused to come out, leaving it looking slightly pink. I also wanted to wet-sand the resin as I've found it to be MUCH nicer than dry sanding (at least for resin), and hoped the varnish would protect the wood from the water.

When all the varnish was dry I applied the resin. I used gold Art Nation mica powder in ResinVentures Art Resin. The Art Resin has proven to be very vulnerable to yellowing, but I didn't feel that mattered in this case, and the mica powder worked much better than my previous attempts at using dyes or GSW metal powders. Being able to use a vacuum chamber (a relatively recent aquisition) to reduce the amount of bubbles in the resin also helped. Of course I passed a heat gun over the surface to pop the rest of the bubbles too; I think the heat gun moving the resin around also helped create a more organic looking pattern.

After giving the resin three days to fully set, I tried sanding the inlay using wet/dry sandpaper in a 3D-printed sanding block. While most of the clear varnish actually got sanded off the wood, and a fair bit of water soaking into the unvarnished wood on the other side, overall it still mostly worked out OK; I didn't notice any real warping of the wood or discolouration from the resin dust. The dark outline came out very nicely too, I'm quite happy with that. I did a quick polishing pass with a Dremel tool and Dremel polishing kit/compound. This did deepen the gold colour a bit and give it a bit more shine, but the wet sanding had already given the resin quite a nice smooth surface so the polishing wasn't too important in this case (I think I used a rather finer grit of sandpaper than I needed to for the initial sanding). Besides, there was still another varnish layer that was going to go over the resin, so the polish was too early (I didn't end up polishing again as it didn't seem to do enough to be worth it to me - especially when the rest of the box ended up looking a little bit rough anyway).

With the box assembled I started the final sanding (dry) to smooth everything out. Once this was done I coated the outside of the box with the clear varnish (applied by brush) and left it for a couple of days. This varnish was not very even; some areas felt very smooth, while others had a rough wooden feel. They actually felt rougher than they had after sanding, as if the varnish had lifted the wood fibres. So I applied another coat, then after giving that a couple of days to dry gave the whole box a very wet sanding. This evened out the surface a bit and actually gave it back a bit of the textured wooden feel, which I was happy about. However in some areas, where I felt the need to sand a bit more heavily as there were some thicker spots of varnish on the surface, I ran into some issues where the varnish didn't sand very well; it almost seemed to gloop up like an almost-dry PVA glue. Perhaps the water, and heat from the friction of sanding, was affecting it?

There were also some spots where the varnish didn't soak into the wood properly, perhaps because of my clumsy use of the wood glue earlier. These spots show up as pale spots and look pretty bad. Overall the final finish is not great, I actually think my previous box came out looking and feeling a bit better. The stained Coprabel varnish was much more expensive than the clear National "synthetic" varnish, so material quality might be a factor. I also dry-sanded that one much more heavily compared to the light wet-sanding I gave this box (to try to get rid of the excessive staining), creating an aged look and a more natural raw wood feel than the varnished look and feel of the new box.

Oh well, maybe the next one will be better. I want to try working with solid wood rather than plywood; I'm also hoping to eventually try using stabilized wood, which should be stronger and not require varnish. Fingers crossed.

A Prototype Deck Vault With Accessory Compartment

This design actually predates the gaming accessory box I posted earlier. It was intended for card games that use dice and tokens, like MtG. It would in theory work for games like Warmachine, but I think the accessory compartment is a little small as Warmachine requires rather a lot of tokens.

It is of course a double-topped design. I engraved a hand of cards on one lid and a dice on the other, to mark the different compartments. The accessory compartment is designed to be large enough for 16mm dice.

This was a prototype; you can see that I used dogbones for the box joints. For a "production" piece I would manually cut the pockets square so there won't be any holes. You can see that the resin inlays in the engravings did not come out very well; I've improved my technique since then, although I still need more practice.

I was using metal powder in two-part epoxy resin; despite my efforts to seal the wood first, some of the resin still seeped into the wood and dropped below the surface. Funnily enough those are the parts that look better; I mixed GSW metal powder into the resin, and it looks pretty good most places where the surface was not disturbed, but not where I sanded the resin flush with the wood, even after polishing with a dremel polishing bit and compound. I also tried to mix alcohol ink into the resin on the card deck symbol, to try to progressively change the colours of the cards, but that didn't quite turn out the way I had hoped. Since then I have obtained some coloured mica powders that seem to give better results.

One issue I'm having is splintering around the lid grooves. This might be partly caused by the quality of the plywood, but it is a bit of a delicate area. For this box I applied superglue to the tongues and grooves of the lids to try to strengthen them and prevent splintering (followed by some sanding to adjust the fit), and you can see where some of that glue got away from me and spread out across the surface. The box was not varnished; hopefully varnish will work to strengthen the tongues and grooves, removing the need for superglue.

I've been planning to take these to the local gaming spot and see if people are interested in having their own boxes customized with their own engraving etc, however I really want to make the final boxes from nice wood, not plywood, and that's surprisingly hard to get around here in appropriately sized sheets - at least with my current budget.