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Wednesday
Jun012016

Maz Kanata's Curio - Lightsaber box

 The Curio Project


 

Thanks for checking this page!  This box was made from hand-antiqued pine, laser cut materials, sculpted epoxy, resin castings, metal hinges, and leather.  

 

 

I have recently developed a kit for the Maz Kanata Curio box.  This kit provides laser cut 1/4 wood segments needed to make the 'metal' trim on the curio that wraps all 6 sides.  It also includes the latch plate and latch head, 40 resin rivet heads, set of 8 nail heads, measurements for cutting your wood sides and templates for creating the handles and dovetails.


What you'll need from home depot is hinges, fence boards and woodstain.

This kit and plans creates a curio box that measures 18.5" wide, 10" tall, and 9.5" deep.   The kit is $89  Shipping in the U.S. is $18.00

CURIO BOX DIY KIT

CURIO BOX DIY KIT

1.) 17 LASER CUT 1/4" COMPLETE set of Trim pieces and latch plate (mdf wood) 

2.) 40 RESIN CAST RIVET HEADS (detailing inside and outside the box)

3.) RESIN CAST LATCH HEAD

4.) PAPER TEMPLATE FOR CREATING DOVETAILS

5.) PAPER TEMPLATE FOR CREATING THE RING HANDLES

6.) set of 8 small nail heads (for latch plate and face)

7.)  instructions

8.) Free access to the VIDEO TUTORIAL.

 

**add $20 for the acrylic rod you'll need for handles and pre-cut leather.


What you'll need to acquire from home depot is fence boards, 3 small hinges, and woodstain.  **power tools, wood working equipment not included.  The 40+ rivet heads are individually sculpted making them unique in size and shape (helping you avoid a machined-look).


To shape your dovetails you can use a bandsaw.  To antique your fenceboards you'll want to have chisels, hammers and dremel with a cut-off wheel.  It's helpful to also have a belt sander and palm sander handy.
CURIO BOX DIY KIT

**IF YOU'RE INTERESTED IN A FULLY FINISHED CURIO BOX, I can be commissioned for a full build.  Email me for an inquiry impervium@hotmail.com


 

 

 

 

 

 

 

HOW IT WAS MADE:


The first thing we needed to do was estimate the rough dimensions.

Pine lumber was my material of choice.  Here we are cutting the boards to their proper specs.  



Cardboard templates were made for the dovetail joints,  traced (positive on one board, negative on its mate) and hand-cut.  

 

 


The most time consuming part (days and days of work!) was antiquing the wood - making it look thousands of years old.  Initially I tested several techniques I found on youtube (steel wool soaked in vinegar, etc..) but those solutions achieved very timid, mild weathering.  Not satisfacatory whatsoever.

These boards were weathered 100% mechanically by hand (chisels, dremels, scraping tools, sandpaper, etc..)  The results are very convincing!!

The box beginning to take shape...... 

The trim pieces were started as cardboard templates...... 

 

...which were then scanned and converted into vector artwork (for CNC machines and laser-cutters.

 

I custom mixed a stain that's a combination of walnut and red cherry. From there it was customized further by adding filters of less viscous stain. 

 

I'm back from the laser cutter.  Here's all the trim pieces (polycarbonate) layed out on the curio.  Some texturing will be needed before painting them with a metallic effect.

The smooth trim pieces were then textured using a special acrylic solution. 

 

 

This is the first rough assembly of the box with it's base colors applied.  The steel hinges are all fully functional.  Weathering/darkening stain layers will be needed to achieve the proper look on both the wood and trim. Right now everything is too new looking.

 

 

 This is my talented shop hand trimming down the screws used to mount the 3 hinges. 

FINIS!!

A closer look at the texturing.

 

For your custom build needs, contact me at impervium@hotmail.com

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