Cut the 6’’ x 12’’ piece of walnut to 4.25’’ x 10.75’’. This can be done using a table saw, circular saw or even a hand saw if need be.
I used double stick tape to hold the work piece. This is important to have access to the profile of your part; otherwise, you will not be able to finish this project. Be sure to use some sacrificial material under the part. One could also build a jig out of some sacrificial material such as MDF, which is why I added it to Bill of Materials.
This is the most important part of this project. It is very important that the center of the end mill is at the center of the bottom left hand corner. Proper alignment is critical for success. This can be ensured by first aligning the X axis. This is done by moving the end mill slightly until it touches the side of the material, and then the Z axis is raised up above the part, and then the X axis is moved to the right by half of the tool diameter. Repeat this step for the Y axis. After this is done, lower the Z axis until the end mill is on the surface of the material.
This is the actual carve process that the project takes. The main one that carves out the box, which takes 56 minutes using recommended settings for 1/4’’ end mill and an engraving that goes on top of the lid that takes 4 minutes using recommended settings for 1/16’’ end mill .
The box will require some sanding because the tolerances are tight; however, this is done on purpose because of slight variances in accuracy from machine to machine. The exterior and interior sides will need to be sanded to allow proper fitment. Sand until it is a tight fit, but the lid should not be very difficult to remove. finally apply finish and allow to cure.
Audrey Van de Castle
Adam St. Louis