Golf Ball Box

Instructions

Box: 1) Resaw and plane 8/4 walnut into roughly 1.25" and 3/8" thick pieces 2) Tape thick piece on shelf for box. I advise setting up multiples at one time for efficiency and physical Origin support 3) Use 1/4" rougher in 1/4" steps with +.04 offset for pocketing and inside cut operations to hollow box using inner circle as guide. 4) Be sure to leave 1/8"-1/4" material for bottom 5) Use 1/4"compression bit gradually removing offset until you reach zero offset 6) Do the same as step 3 for the outer circle, this time with an outside cut all the way through to shelf. 7) Follow step 4 Lid: 1) Tape thin piece on shelf for lid. Make same number as boxes as noted in step 2 2) Use 1/4" compression or regular upcut with +.04 offset as outside cut using inner circle as guide. 3) Go as deep as you want the exposed lid to be thick 4) Using same bit, gradually remove offset a little each pass and test fit box until you get a nice press/slip fit. Don't worry if you get zero offset and the lid doesn't fit, depending upon the wood and bit used this could even end up as a negative offset so just keep creeping up on the perfect fit. Origin is awesome for this! 6) Do the same as step 2 for the outer circle with an outside cut all the way through to shelf. 7) Remove offset a little at a time and test fit until rim of lid is flush with box. In theory offset should end up at zero but you should check as you go along. Outside Lid Engrave: 1) Use 1/16" bit as inside cut/pocket for all of the small details. Depth was roughly .1" 2) Use 1/8" bit to clear out/pocket the larger areas. Inside lid engrave [optional] Sanding: Cut a short piece of dowel (I used 1/2" diameter and 2" length) and affix a small piece of 220 sandpaper on the end with CA glue and kicker. Then trim sandpaper with scissors to tight circle. This chucked up in a cordless drill makes a great way to sand box bottom quickly! Sanded the edges together with the lid in place to get the perfect fit. Last minute oops adjustment: Once I got the boxes done I realized some people may have trouble opening them. Easy solution was to take a round needle file (I used an oval one) and while you can't see it in the pictures, I filed a little notch in the top edge of the box for a fingernail catch. Looks clean and makes using them nicer. Finish: Use your favorite finish here. I used General Finishes Arm-R-Seal Satin for all exterior faces of box and lid. The real tip here is to mask off the inner faces of the box and lid where they go together and don't get any finish on the mating surfaces. For the inside of box and lid and mating surfaces I used Howards Butcher Block Conditioner which is basically mineral oil and beeswax. Apply and wipe off completely right away and let soak in for a couple days. If you are careful doing this, the fit will stay perfect.