4-sun 18-step box (2)
I only had time to work in the morning today, but I focused on creating and assembling the frame for the 4-sun 18-step Japanese puzzle boxes I started making yesterday. This time, I’m producing a slightly larger batch of 60 pieces, so each task takes a bit longer than usual. As seen in the photo, there are noticeably more parts than usual!😅
Even during large-scale production like this, I try to make the process less monotonous by adding some variety. For example, I might include a few boxes with new designs. Since this batch is mostly made-to-order, many of the boxes follow the specified design—traditional Yosegi with the Ichimatsu (checkered) pattern. However, I’ve made a few extra for myself, and I’m considering adding some solid wood designs to the mix.
That said, the made-to-order boxes in this batch use side panels covered with Yosegi sheets in the Ichimatsu (checkered) pattern. If I were to use solid wood for the side panels, the making process would differ from the standard Ichimatsu design boxes.
Therefore, for my inventory pieces this time, I’m considering using solid wood only for the top and bottom panels while keeping the side panels in the same Ichimatsu design. Ideally, I’d love to use unique solid wood, but we’ll see how it goes🧐
The second photo shows the assembly process of the frame. For a puzzle box where all four sides move, the strength of the box relies solely on the adhesion of the axes and the frame panels. This is why I take extra care to ensure a strong bond. The amount of adhesive is critical, as is the quality (or condition) of the adhesive itself.
As you may know, wood absorbs moisture through the end grain, which is how it retains its internal moisture. Naturally, it also absorbs adhesive in the same way. To make the wood less likely to absorb the adhesive, using a thicker, less watery adhesive is ideal. However, if the wood absorbs no adhesive at all, the glue will only adhere to the surface, making it prone to peeling off with minor impacts.
The ideal condition is when the wood absorbs just enough adhesive while leaving enough glue for a strong bond. Adjusting the moisture balance of the adhesive is crucial to achieve this. Additionally, different types of wood absorb adhesive differently, so it’s also essential to make adjustments based on the wood species.
I plan to continue with the next steps of this process tomorrow.
Even during large-scale production like this, I try to make the process less monotonous by adding some variety. For example, I might include a few boxes with new designs. Since this batch is mostly made-to-order, many of the boxes follow the specified design—traditional Yosegi with the Ichimatsu (checkered) pattern. However, I’ve made a few extra for myself, and I’m considering adding some solid wood designs to the mix.
That said, the made-to-order boxes in this batch use side panels covered with Yosegi sheets in the Ichimatsu (checkered) pattern. If I were to use solid wood for the side panels, the making process would differ from the standard Ichimatsu design boxes.
Therefore, for my inventory pieces this time, I’m considering using solid wood only for the top and bottom panels while keeping the side panels in the same Ichimatsu design. Ideally, I’d love to use unique solid wood, but we’ll see how it goes🧐
The second photo shows the assembly process of the frame. For a puzzle box where all four sides move, the strength of the box relies solely on the adhesion of the axes and the frame panels. This is why I take extra care to ensure a strong bond. The amount of adhesive is critical, as is the quality (or condition) of the adhesive itself.
As you may know, wood absorbs moisture through the end grain, which is how it retains its internal moisture. Naturally, it also absorbs adhesive in the same way. To make the wood less likely to absorb the adhesive, using a thicker, less watery adhesive is ideal. However, if the wood absorbs no adhesive at all, the glue will only adhere to the surface, making it prone to peeling off with minor impacts.
The ideal condition is when the wood absorbs just enough adhesive while leaving enough glue for a strong bond. Adjusting the moisture balance of the adhesive is crucial to achieve this. Additionally, different types of wood absorb adhesive differently, so it’s also essential to make adjustments based on the wood species.
I plan to continue with the next steps of this process tomorrow.
