Making fly boxes from scratch...or pine.

Remember a few months ago, when the weather was warm and the fish were biting and there was the occasional light warm breeze out of the south?  That was awesome wasn't it?  During that same time I ran across an interesting post on The Fiberglass Manifesto that featured a company called Blackland Woodworks.  The post showed how the owner makes beautiful fly boxes from scratch and it got me thinking about trying my hand at the same project.  Like I said, this was during a time when you could actually go fishing so I didn't pursue this project right away.  However, since the weather has turned and I have some time to dedicate to more "indoor friendly" projects, I am making an attempt at my own version of one of these boxes.

A Blackland Woodworks custom-made fly box.  Beautiful huh?

Here's a link to the posts I read that inspired my own project: http://thefiberglassmanifesto.blogspot.com/search?q=blackland 

As with most of my woodworking projects, there has been a definite learning curve.  While I am not skilled enough to get things perfect the first time, I am experienced enough to know that I am not going to get things perfect the first time.  I don't get frustrated as a result and now I just expect to encounter obstacles.

I stared off with a piece of cheap pine from Lowe's.  I chose a piece that did not have knots (kind of difficult) and a piece that was not warped (even harder).  I knew that this would be my prototype so I wasn't incredibly picky.  I then determined my dimensions in terms of length and width.  I then ripped the board to be 4 1/2 inches wide.  Next, I sketched out the sizes of the boxes on the wood, accounted for the width of the saw blade when I cut the pieces later, and determined the distance from the edge of the box to the pocket that I was going to router.  I also accounted for space to insert magnets and pockets for hinges.  I didn't like the way the hinges were on the outside of the frame for the Blackland Woodworks box so I decided to embed them inside the box to make it look nicer but still close flush.

The notes are reminders about where I made mistakes.  You can see where the router got away from me and where I tried to recess the hinges.  Ugly huh?

Here's what I have learned so far.  Routers are hard to control even with a guide attached to the router, and smaller bits are both more forgiving as well as useful for making corners that are less rounded.  When making a pocket for the hinges to set inside, it is important to remove layers or wood so you work with the grain rather than against.  Using cheap wood as a prototype hurts less when your all your work gets tossed in the trash can because I got carried away with router depth.  Rounding over the edges of the outside of the box looks really nice.  Taking a torch to the outside of the pine box looks really cool!

The outside of the box from above that I burned with a torch.

This is still a work in progress but I am getting closer to finding the process that will turn out the product in the exact way I want.  I am now experimenting with some magnets that I want to use to keep the boxes closed and purchased some more expensive wood.  I am also experimenting with some different types of foam and felt that I might use to secure the flies to.  I will post again when I am perfected my process and let you know about what else I learned.

Things I have learned:

I changed to a smaller router bit.  This allows for errors to be less glaring and easier to fix.

I made a jig on the advice of some friends.  This maintained a framework to keep the router within.

A blank fits in the jig tightly.

At the bottom of the base of my plunge router, a guide keeps the router inside the jig.

These blanks were routed with a 1/2 inch bit.

These blanks were routed with a 1/4 inch bit.

The hinges were recessed and I burned these blanks as well.

Prototype #2.  The felt was easy to shape and fit, but DO NOT put a fly in the felt beyond the barb...unless you never plan on using the fly again!  

The hole for the magnet is too large and I have since bought a bit that will ensure a more secure and snug fit.  I wish I could find some magnets that are smaller in diameter as well.  However, the magnets are strong and hold the box closed really well.

Left side of the same box.  You can see where the hole I drilled for the box kind of "blew out" the side of the box.  Oops!  That won't happen again!

I will post again when I have perfected this process, but I feel like I am getting close to a process that will work for me and produce a really nice box.