13-Aug-2024
The process of making the 27-step Japanese puzzle box up to the finishing stage: puzzle box features a lid panel made of natural wood and a side panel design with a checkerboard yosegi pattern that I crafted myself. The side panel is divided into three parts, with slide key panels on both sides, which are then attached.
Let’s look at the process of attaching the panels and applying the base coat. On the first day, I attach one of the side panels with the slide key mechanism to the box. Then, I secure the attached panels with rubber bands and let them sit for a full day. The reason for leaving them for a day is that the panels tend to warp due to the moisture in the glue, so this allows them to settle. Additionally, since the panels with the slide key mechanism are divided into three parts, this step also ensures they stay aligned without shifting.
The next day, I attach the other side panel with the slide key mechanism, and I let it sit for a full day, just like the first panel. As I mentioned other day, the weather is crucial during this process. The panels must be attached on a dry, sunny day to prevent them from absorbing moisture. This helps to avoid any gaps forming between the main body of the box and the panels later on.
Once the two sides are attached, the next day I round off the corners of the puzzle box. This is done on the day of the base coat, just before applying the base coat. After rounding the corners, I lightly sand the entire surface and then proceed with the base coat. I prefer to do this corner rounding work in the morning to avoid over-drying the box. At this stage, the rubber bands that were holding the side panels with the slide key in place have been removed, so if the side panels become too dry, gaps can form between the panels and the main body of the box. Until this point, the rubber bands have been preventing the panels from warping. For example, on a hot summer day like today, the sun is stronger and it’s easier for things to dry out in the afternoon, so I do this work in the relatively mild morning. Then I immediately apply the base coat. The base coat helps to seal the wood grain on the surface of the panels, preventing the wood from losing moisture. These process takes a total of three days.
I’m very careful at this stage of the process. Fortunately, the weather in my area has been dry lately, so the side panels were attached in good conditions, and no gaps have formed. I’m glad!😁
By the way, I also completed the same process for the 3-sun 7-step Natural wood boxes at the same time.
