I had an opportunity to create a Toy/Costume chest for two lucky little boys for Christmas. This was my first attempt at making a chest, and I think it came out quite well.
The first step was building the box. 3/4" Red Oak plywood, dovetailed together. Dovetails were done on the CNC. A lot of chip out on the edges, but I wasn't concerned because it was going to be covered anyway.
After that I cut out the 'metal banding', also on the CNC. I used a textured toolpath to create a 'forged' effect to match the hardware that I would be installing later. Took about 6 hours to run through all the trim, but I neglected to set my safe Z lower, so there was a lot of unnecessary Z movement that added time.
With the box banding complete, I set out to create the lid. I cut the end pieces and ribs on the CNC, glued the frame together, and then wrapped it with 1/8" Red Oak plywood. I used more more MDF faux metal banding on the lid as well.
Next came the nails. I was going to use screw hole 'buttons' and file them down by hand, but when I was looking through the hardware section of the Lee Valley catalog, I came across some forged iron nails. $16 for 200. Sold.
Almost finished! The next step was to prime the trim with Acid Blocking primer, and then paint it with Modern Masters Iron paint. I wanted to use the comparable Sculpt Nouveau product, but it was special order and I didn't have time to wait for it. After painting I lightly spritzed it with some Modern Masters rust accelerator, and then sealed it with Varathane Satin Interior Finish just as it was starting to rust.
I then stripped off all of the masking, and put a few more coats of Varathane Satin over the entire project. I sprayed the interior flat black, mounted the handles on the sides, and that was all she wrote!
The quote is from the author of Peter Pan, and it wraps all the way around the box. "So come with me, where dreams are born, and time is never planned. Just think of happy things, your heart will fly on wings. Forever in Never Never Land!" The M in the middle of the box stands for the Client's family name, and was Prism Carved out of MDF. It was then also painted with Iron paint, and sprayed with Sculpt Nouveau 'Black Magic' and left to react fully (not rinsed off).
Thanks for looking!