45 ACP .. A well made cigar box with upgraded Hinges....

 A good size box for a Group Therapy sessionRefitted with: "Phil Miracle Foam"

9mm Luger: .. Plain Jane Cigar Box .. with upgrades .. complete.

A Plane Jane; but well made box: overall size 9" x 6.750"Upgraded with Brass LatchFitted with upgraded hinges. Foam (off cuts) Risers .. mitered corners keep them in place.Box and Insert...ready to assembleInsert inserted.9mm Luger Loaded into a 12 x 9 matrix ...108 rounds

38 Special ... very SPECIAL

A very good size box for 38 special.
Note the angled Left and Right sides, extra challenge...

Foam Insert .. perfect fit.

Loaded box, 117 round

When is a Cigar Box, not a Cigar Box???? ... "Open Sesame"

5 new 22LR Competition Ammo Boxes (UPDATE>>>>)

Colour Samples on FOAM BLOCK ... Left to Right: Cherry Stain, Dark Walnut Stain and No Stain.

5 Boxes: Top 3 combination of Oak and Walnut ..Bottom 2 all Walnut 

2 Boxes one with Walnut Stain on Foam Inserts, One with Cherry Stain (UPDATE.. Restained the Cherry Blocks with WALNUT, now all the same...)

Both Boxes loaded with 50 Rounds (Cherry Stain then Walnut Stain) 

Both Boxes ready to Go !!!

All 5 Boxes loaded:

New Boxes: 9mm.

Inserts using a HIGH DENSITY FOAM Board (Left)...and A COMPOSITE PLASTIC Board (Right) This Reduces the weight by 40+% over Wood Inserts.

Friday PM Wrap-Up

44 Blocks all processed through the Table saws... One saw set for 10 degree Face Cut .. Other Saw Set for Rip and Crosscut .. Also squared up the remainder of First Sheet of Foam Board .. also squared up Second Foam Board .. Set-Up Drill Press for Lower Row of 5 Holes .. Drilled one Block with all 10 Holes ...

Blocks ready for drilling Lower set of holes:Set-Up and Test Blocks; Three Poplar and Three Foam

Processing New Material .. New Blocks

Using a High Density Foam Board: Very easy to Saw and Drill. No resistance, so requires diligence.  Spent Wed, evening experimenting with various Saw set-ups and process sequencing.

Set to Drill at Station #1 Top Row. Top Row: 5 Holes.Processing through 44 blocks .. 8 sets of 5 plus some spares. 

Tuesday AM ... Wrap-Up .. Caught Up

 Tuesday morning: 

1) Finished up mounting Router Plate into the Table Saw Wing.  This a much more stable / no flex 10mm, 0.395" thick Plate (replacing the thinner one, only 1/8", 0,125", 3.17 mm)  recessed into wing.2) 22LR Boxes and Inserts complete.

Monday .. Very busy full day

Finished up the 22LR Box Build .. Finish continues to dry. 2 Boxes are being refinished .. All American Walnut boxes.  4 New Boxes a combination of Oak and Walnut, and 20 new 10 round Inserts, Poplar.

Built a New Router Base for my Ryobi Router. Use a 10x200x200mm Red Phenolic Resin Flat Sheet. .. Will test it later.

Sunday .. PM overview

3 Lids in Last Glue-Up ... Block Stop in the lid used when box is closed 1 Box assembled to test Hinge and Latch .. great fit .. Block Stop in Glue-Up

Sunday early AM... Drying time

 Boxes 1 & 2 get a 2nd coat.. boxes 3-6 drying after first coat20 new blocks are dryPutting the boxes out in the Sun; air is still cold..... probably need another day to dry.

Saturday ... lot of set-ups and assembly / disassembly and applying finish..

Setups in the Drill Press; 8 parts, 5 holes in each; 3 holes for hinges & 2 holes for latches. Setup shows a Lid clamped ready to drill 3 holes for a Hinge.

After much ado; parts coated with Danish Oil and now to let them dry, planning on 3 coats total. All in all, a very good days result . 

Friday .. progress continues ....

Mounted and Set-Up the Vice on the Drill Press Table .. set to Drill a 0.0626" hole for mounting Piano style hinge for the Lid and Base...

With the Bases and Lids all cut to length .. time to attach the short ends. Eight Glue-Ups enjoying the clear warm Sun

Sanded both bases and lids .. also trimmed excess material from end trim .. Cut 20 degree surface on one end of the bases. .. Finished router edge round-over.  Tomorrow: finish sanding, then apply Danish Oil.

Friday Ante Meridiem ..Update..

Managed to get all the Long Sides into Glue-Up yesterday .. using the parallel clamps to augment the Vices ... A base in one vice and a Lid in the other.