jonny round boy
Member
- Joined
- Jul 21, 2007
- Messages
- 3,227
As you may know if you've read my earlier post, my partner Kate recently passed away.
Whilst planning the funeral I did a little research and decided to make her coffin myself, rather than purchasing one - that way, I could make something a bit less traditional, and something that would be very personal. Kate & I did discuss me making her a coffin a few months ago. Kate joked that it was a great idea, as obviously she'd then have to live forever, because I "never finish anything"!
I wanted something fairly modern, but not completely 'out there', and decided on a traditional tombstone shaped oak box, with a continuous band of walnut around to act as the handles. I started drawing up some ideas on SketchUp, and after a few revisions came up with this:
[attachimg=1]
The lid is inset into the sides, which is slightly unusual for a coffin as the lid usually sits on top with a moulding around the edge to form a lip. Since this inset lid cannot be screwed down in the usual manner, I decided to use walnut through-dominos which could be knocked into place to fix the lid permanently. I also added matching ones to the base.
I ordered 2 sheets of oak-veneered blockboard (most coffins in the UK are veneered chipboard, but blockboard was the nearest I could get) along with a few pieces of solid oak and walnut, and some iron-on oak edging.
I began work on this on Saturday. The main pieces were cut with my TS55 which was all very straightforward. Since the sides were curved they needed kerfs cutting in. Again, the TS55 was used:
[attachimg=2]
Gluing up the pieces was a little tricky, as I was working on my own and there's a lot of edges to glue all at once! Here's a couple of pics:
[attachimg=3]
[attachimg=4]
Once it was glued up and dry, I flipped it over and edged the bottom edges of the sides & ends. Then I sanded the underside and added a coat of Danish oil, since I wouldn't be able to do that at the same time as oiling the rest:
[attachimg=5]
After applying edging to the top edges, the blocks for the handle supports were cut next. I'd got the oak planks planed to 25mm finish, so it was just a case of cutting them with the TS and panther blade. I cut one of the curved pieces with the Carvex and sanded it, then used that as a template to make a second on my router table. These are glued and screwed from the inside:
[attachimg=6]
[attachimg=7]
Since I last took some pictures I've ripped some of the oak down into 10mm wide strips, and added a lip around the inside of the top edge to carry the top panel.
Unfortunately, the pieces of walnut I got are no good - I ordered it before I'd completely finalised the design, and they're no longer long enough! [embarassed] Also, they're quite knotty and probably wouldn't bend very well. I've contacted the guy I got it off, and I'm hoping he can machine some more for me when he gets back in tomorrow, for me to collect on Wednesday. Then all I've got to do is build a steam box, steam-bend the two side pieces, round the edges over, sand them, mitre them, fix them in place, and get some oil on them, in time to deliver the coffin to the funeral director's on Thursday!!! [scared]
I hope to get some oil on the rest of the box tonight, and then get the walnut done on Wednesday (I'm working tomorrow). I seem to work better with a deadline looming, and I certainly can't miss this one!
Jonathan
Whilst planning the funeral I did a little research and decided to make her coffin myself, rather than purchasing one - that way, I could make something a bit less traditional, and something that would be very personal. Kate & I did discuss me making her a coffin a few months ago. Kate joked that it was a great idea, as obviously she'd then have to live forever, because I "never finish anything"!
I wanted something fairly modern, but not completely 'out there', and decided on a traditional tombstone shaped oak box, with a continuous band of walnut around to act as the handles. I started drawing up some ideas on SketchUp, and after a few revisions came up with this:
[attachimg=1]
The lid is inset into the sides, which is slightly unusual for a coffin as the lid usually sits on top with a moulding around the edge to form a lip. Since this inset lid cannot be screwed down in the usual manner, I decided to use walnut through-dominos which could be knocked into place to fix the lid permanently. I also added matching ones to the base.
I ordered 2 sheets of oak-veneered blockboard (most coffins in the UK are veneered chipboard, but blockboard was the nearest I could get) along with a few pieces of solid oak and walnut, and some iron-on oak edging.
I began work on this on Saturday. The main pieces were cut with my TS55 which was all very straightforward. Since the sides were curved they needed kerfs cutting in. Again, the TS55 was used:
[attachimg=2]
Gluing up the pieces was a little tricky, as I was working on my own and there's a lot of edges to glue all at once! Here's a couple of pics:
[attachimg=3]
[attachimg=4]
Once it was glued up and dry, I flipped it over and edged the bottom edges of the sides & ends. Then I sanded the underside and added a coat of Danish oil, since I wouldn't be able to do that at the same time as oiling the rest:
[attachimg=5]
After applying edging to the top edges, the blocks for the handle supports were cut next. I'd got the oak planks planed to 25mm finish, so it was just a case of cutting them with the TS and panther blade. I cut one of the curved pieces with the Carvex and sanded it, then used that as a template to make a second on my router table. These are glued and screwed from the inside:
[attachimg=6]
[attachimg=7]
Since I last took some pictures I've ripped some of the oak down into 10mm wide strips, and added a lip around the inside of the top edge to carry the top panel.
Unfortunately, the pieces of walnut I got are no good - I ordered it before I'd completely finalised the design, and they're no longer long enough! [embarassed] Also, they're quite knotty and probably wouldn't bend very well. I've contacted the guy I got it off, and I'm hoping he can machine some more for me when he gets back in tomorrow, for me to collect on Wednesday. Then all I've got to do is build a steam box, steam-bend the two side pieces, round the edges over, sand them, mitre them, fix them in place, and get some oil on them, in time to deliver the coffin to the funeral director's on Thursday!!! [scared]
I hope to get some oil on the rest of the box tonight, and then get the walnut done on Wednesday (I'm working tomorrow). I seem to work better with a deadline looming, and I certainly can't miss this one!
Jonathan
