This handcrafted music box is sure to become a cherished family heirloom. Even without the musical movement, the project makes a beautiful keepsake box. Try experimenting with different options—line the inside with silk or try a backing board with flocking; scroll just the top and leave the sides solid. You could even alter the pattern on the lid to include a monogram or special symbol. Customizing the box makes it a one-of-a-kind gift that is sure to please.
Step 1: Prepare your blanks. Cut all the pieces to the dimensions listed in the materials list. Sand all the pieces with progressively finer grits of sandpaper up to 220-grit.
Step 2: Prepare the side pieces for stack cutting. Stack the two blanks for the long sides and the two blanks for the short sides. Attach the blanks together to stackcut, using your method of choice (painters’ tape, hot glue, double-sided tape, etc.).
Step 3: Transfer the patterns to the top, bottom, and side stacks, using your method of choice (temporary bond spray adhesive, carbon paper, or graphite paper). Fold the patterns for the feet along the dotted line, and attach them to the blanks, using temporary-bond spray adhesive.
Step 4: Drill blade-entry holes for the interior cuts on the top, sides, and bottom. Use the smallest drill bit that a #1 blade, or your blade of choice, will fit through. Drill the 3/8"-diameter hole in the bottom for the music box key. Mark and drill the pilot holes for your hinge screws at this time as well.
Step 5: Make the interior cuts on the sides and top. Start in the center with the #1 reverse-tooth blade and work your way out. Cut the slots on the bottom for the side tabs. Try to keep these slots as square as possible so the side tabs fi t in tightly.
Step 6: Cut out the perimeter of the top, bottom, and sides. Use a #5 reverse tooth blade. It is possible to stack the top and bottom together, using double-sided tape or hot glue. That way the scalloping around the edges will be exactly the same.
Step 7: Cut out the box’s feet. You only need to cut out the rear view on the scroll saw since the top view is the exact dimensions listed in the materials list. Use a #5 skip-tooth blade. The piece is very thick (11/4"-thick), so use caution, and let the saw cut at its own speed. If you try to cut too fast, the saw blade will bend, and you will get an angled cut.
Step 8: Sand the pieces with 220-grit sandpaper to remove any burrs. Apply your finish of choice. A good choice would be to dunk the pieces in Danish oil or boiled linseed oil. Dunk the pieces, bring them out, and suspend them so the oil will drain off.
Step 9: Assemble the box according to the assembly diagram. Run a bead of glue along the ends of the short sides, and nail the pieces together with small brads where indicated on the pattern. Glue the tabs on the long sides into the holes in the bottom. Make sure the screws for the hinges are not so long that they will penetrate through the wood of the top and side and attach the hinges.
Step 10: Glue the feet in place on the bottom where indicated on the pattern. Use your wood glue of choice, and clamp the pieces overnight. Attach the music box movement to the bottom where indicated on the pattern. Follow the manufacturer’s directions to install the music box movement.
