Yusanbako

Aug. 14/2021
Yusanbako is Traditional Lunch Boxes in Tokushima JAPAN.Nowadays, colorful Yusanbako are on sale. I made a simple one that makes the best use of the grain of wood. The material is cedar, and the size is such that it can be made with two 250 * 900 * 10t pieces.Drawing
1.I decided to make the outer box with finger joint. However, I didn't have a template with a groove width of 10 mm, so I made it from plywood. First attach the plywood to the jig and cut a groove with a 10mm bit. Next, insert two 10 mm keying materials between the jig and cut a groove.
Go to finger joint jig
2.A groove with a pitch of 20 mm.
3.Drilling for air intake.
4.Glue a 10mm wide positioning bar.
5.The lower two templates are 8mm and 15mm wide, which were made with MDF.
6.Cut 10mm thick cedar wood to the size of the outer box.
7.Making finger joint. If you cut a groove with a depth of 10 mm in one shot, the board seems to burn, so it took longer than I expected because I cut it in two steps.
8.The front side of the top plate. Cut a 6mm wide groove for the sliding door.
9.The left and right of the plate will put the cut-out pattern. Laser engrave a large tree mark on the left side.
10.Engrave the cherry blossom petals on the right.
11.Cutting out the cherry blossoms was quick and easy.
12.The large tree has 39 cutouts, which was a tiring task.
13.Counterbore 9mm for M3 nuts to attach handles to the top plate.
14.Drilling 3mm through hole.
15.Cut the thickness of the part that goes into the groove of the slide door and the upper part to 6 mm.
16.Cut the periphery with a 90 degree bit to an inclination of 45 degrees.
17.This is a pull-up bar attached to the top of the sliding door. First cut a 6mm deep groove.
18.Then cut to 10mm width.
19.After gluing the pull-up bar to the door, insert a 3mm bamboo skewer just in case.
20.This completes the outer box !!. It have to do is apply Watco oil.
21.The sliding door moves smoothly.
22.From here, it's the process of making the nest of boxes. First, cut the end face to 45 degrees with a miter jig.
23.Glue with a yellow bond while checking the right angle.
24.Grooving for the spline slot.
25.Used rosewood for the spline slot.
26.This is the lid of the nest of boxes. Cut the four sides of the lid to 45 degrees.
27.Make a 3mm step on the back of the lid.
28.This completes the nest of boxes. Wonder if the plate thickness 10mm is a little too thick.
29.I noticed that I forgot to make a hole in the back of the outer box to push out the nest of boxes. Drilling with a Forstner bit 20 mm.
30.Engraved the picture of a cherry to the sliding door with a laser.
31.Engraved my brand mark on the back side.
32.It was also engraved on the lid of the nest of boxes.
33.Finish the outer box with clear Watco oil, and the nest of boxes with water resistant "Kigatame ace" three times and then finish with it clear.
34.Engraved cherry blossoms on the sliding door. I wonder if it should have been a little darker.
35.This is the cutout part of the cherry blossom petals.
36.This is the cutout of the large tree.
The storage state of the nest of boxes.
I think it's simple and nice.

[Home]