Why would anyone want to design and build a round jewelry box? Mostly because when I looked online to see what one would look like I was disappointed to see nothing on the subject. So I started drawing and thinking, sometimes all at the same time!
It started with rough lumber, turning on a lathe, and then assembly and finishing. There is a post here: http://www.buildncook.com/turn-turn-turn that shows the first stages and the turning process.
After the drawers were all turned on the lathe, I had to put a bottom in each of them and then cut thin stock to make the dividers in each of the drawers. I used some leftover 1/4″ plywood for the bottoms and more of the same wood (poplar) for the dividers. Cut groove for the bottom on the router table, and cut out the bottoms with a hand router. Then glue the bottoms in place.
The dividers were just a lot of cutting, planing to thin as possible, fitting and gluing the pieces together and then the assemblies into the drawers.
It was finally time to make the hinge system so the drawers can open and close. The top and bottom pieces for the project were cut out with the router again, then the bottom rounded over and the top sculpted on the router table. The hinge uses sections of hard plastic pipe for a bushing and a steel rod for the hinge pin. I used some silicone grease to lubricate it all as it was assembled.
The next thing I did was to apply semi-gloss polyurethane over an oil based stain on the outside of the unit. I used matte poly on the inside of the drawers to get them ready to be flocked. The flocking process is detailed here: http://www.buildncook.com/get-the-flock-out
Once the drawers were finished a flaw was discovered in the top of the unit. The wood cracked where I used screws and glue to attach it to the upright. I did the best I could to repair the crack but it was very noticeable so I had to find a fix for that or else make a whole new top piece.
My solution was to make a sheet of veneer of the same wood and install it over the top. Making veneer is another new experience for me, cutting some thin slices on the table saw and then edge gluing them to make a wider sheet of wood, then mounting that onto a backer board and running it through the planer. I managed to get it to 3/32″ thin before the planer started making confetti out of it, so that’s what I used.
Rough cut to oversize of the top and then glued into place after sanding the finish off the original top piece. I was surprised at how easy this process was. Again, lots of glue and clamps to be sure it is secure. Then the same bit used to shape the top edge was used to sculpt the edge to the exact size. Some final sanding and then two coats of stain on the new piece of wood. Followed by 4 coats of semi-gloss polyurethane. The repair is hardly noticeable, which is the way it should be.
So now there is a round jewelry box for future generations to build upon. I already could make some improvements if I were to build another one, but I’m content with the final outcome of this project.