This project was built and designed by Jay Bates. It’s a series of custom wooden boxes made from figured maple and detailed with walnut inlays—an elegant way to craft meaningful, handmade gifts.
These boxes are designed with care and precision, featuring wraparound grain, beveled corners, and clean panel joinery. Built as a Christmas gift idea, the boxes combine beautiful materials with smart woodworking techniques that elevate a small project into something special.
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Choosing Figured Maple for Character
Jay begins by selecting curly and spalted maple from a trusted source, Bob Kloes, who specializes in figured hardwoods. Rather than opting for clean, defect-free stock, he intentionally picks a board with visible character.
The key insight here is that the most attractive figure in a board often appears on the bark side. Even wood with small cracks or flaws can be turned into a beautiful box when cut and positioned thoughtfully.
Milling and Preparing the Stock
The boards are first rough-cut using a jigsaw and bandsaw. Jay then flattens them on the jointer and thicknesses them with a planer to prepare them for box sides and panels.
He points out that figured wood responds differently depending on the cutter head. In this case, a helical head reduces tear-out and leaves a smoother finish compared to a traditional straight knife cutter.
Creating a Continuous Grain Pattern
To maximize visual appeal, Jay resaws the stock and cuts the sides in sequence to wrap the grain around the entire box. He uses spacer blocks with a miter saw for repeatable, accurate cuts.
This layout technique ensures that each corner flows naturally into the next. It’s a subtle detail that experienced woodworkers and recipients alike will notice and appreciate.
Beveling the Edges for Clean Joinery
Instead of using butt or miter joints, Jay bevels the box corners using a setup with dual miter gauges and a sacrificial fence. This results in tight-fitting, seamless joints.
Before committing to the final pieces, he tests his setup using scrap. This step minimizes mistakes and ensures everything lines up properly once the real cuts begin.
Building the Panels with Veneered Plywood
For the box top and bottom, Jay glues maple veneer onto plywood to improve dimensional stability. This reduces the chance of movement or warping while maintaining a consistent look across all sides.
Once the glue dries, he rabbets the box pieces so the panels can fit snugly and flush within the box frame. It’s a clean, strong method that keeps the overall build lightweight without compromising on strength.
Preventing Glue Stains and Ensuring Clean Assembly
Jay uses painter’s tape on the inside faces of the box to prevent glue squeeze-out during final assembly. It also doubles as a clamp, holding the corners in alignment while the glue sets.
To spread glue evenly, he uses a basic chip brush—an affordable and effective choice. Taking time on this step ensures the interior remains clean and requires less sanding later.
Adding Walnut Inlays for Contrast
For an extra design element, Jay adds thin strips of walnut along the top and bottom edges. These inlays provide contrast and help frame the lighter maple body.
He cuts the strips carefully, fits them tightly, and uses painter’s tape to secure them during gluing. Hand planes are used to level the inlays, resulting in a smooth and flush surface that looks professionally crafted.
Final Assembly: Lid Separation and Hinge Installation
With the box assembled, Jay separates the lid using the table saw. This step requires patience and accuracy to ensure the cut is clean and doesn’t damage the sides.
He marks hinge locations, routes shallow mortises with a trim router, and fine-tunes the fit with a chisel. The hinges are then installed flush with the back, allowing the lid to open and close smoothly.
Sanding and Finish
Before finishing, all surfaces are sanded smooth with attention to the edges and inlay areas. Jay uses shellac as the final finish, which brings out the depth and shimmer of the curly maple.
Shellac is chosen for its warmth, fast drying time, and ease of repair. It’s a fitting choice for gift items where both beauty and practicality are important.
An Elegant Gift with Handmade Value
These boxes are a perfect example of how woodworking can be both functional and expressive. Whether for holidays or special occasions, a handmade box like this holds more meaning than a store-bought item ever could.
Jay plans to add additional embellishments in a follow-up video, but even in this state, the boxes show how simple materials and thoughtful techniques can result in high-quality, personalized work.
Please support Jay by purchasing his plans here: Jay’s Custom Creations.