Normally when I design projects, I like to sell the corresponding CNC Files for all of you at home to try making things yourself. When it comes to this "zippo" style ring box, my plan is to do just that...at least after I work out all of the kinks. This is just the prototype.
I rushed through making this the other night because I had an idea in my head I really wanted to try. For the real version, I plan to make a full Youtube Tutorial on my channel to fully explain my process.
A friend requested this style ring box for an engagement ring and asked that I include a sunflower on the side. Keep in mind that this piece of wood was cut down to specific dimensions I pulled from a jig that you'll see me make in the next step of the project.
The CNC toolpaths for the sunflower are a shallow pocket with a 1/16" Downcut Bit at .04" depth. Using Oramask, I'm able to add color fairly easily using Unicorn Spit. For the final version, my plan is to use epoxy instead, making the finish glossy smooth. I also want to shrink the project a bit, making it closer to the size of an actual zippo lighter.
In order to carve pockets for magnets and barrel hinges, I made a jig. Using the CNC and a single piece of 1" Teak I got from Lowes, I designed and carved 3 components and glued them together using dowel locator pins. I also included a small area on the side where I could use clamps to secure it to the waste board on my machine. This ended up working out well, but I will admit I made some small mistakes on the jig that required some post machining corrections. Lessons learned for next time.
The carving of the ring box itself was extremely simple once I hammered the pieces into the jig. Using a 1/8" and 1/4" Downcut but I carved pockets based on measurements I took off my hardware earlier. The ring pocket I probably made too big, but I can adjust that when I shrink the final version. As for adding a velvet inner lining that secures the ring in place, I'll work on that once I get the main body tuned in how I like it. That can wait.
After carving, I popped the components free by hammering a dowel through the bottom of the jig. Luckily, because of those post machining corrections I mentioned earlier, I thought to drill holes in the bottom before carving anything.
Once free, I shaved and cut down a piece of scrap wood so it would tightly fit in the ring pocket and hold the two parts together using friction. This actually worked much better than I thought, but next time I would also dry fit the hardware at the same time to keep things more perfectly inline.
Once friction tight, I used a 1/4" round over bit on my router table to smooth over all the edges. This is also something I might adjust on the real version. I want to make things less...blocky.
From there, I quickly added a few coats of lacquer and installed magnets and barrel hinges using CA Glue. I sized the magnet pockets correctly, but my hinges still come slightly loose upon opening because the holes aren't tight enough. That, and I also left too much material, like 1/16", behind the body of the hinge, so the parts push off each other when its open. Always room for improvement.
Overall, I think this prototype shows a whole lot of potential for a really unique final product.
Drop a comment if you have any ideas!
- Justin
