Creating a case for a box is really just the same as you would do it for a book. You need a lid, base, and spine.
I measured a piece of cloth that would give me about a 1-inch margin all around. After test fitting it, I glued out the first board with mixture and applied it to the cloth.
Then I placed my triangle along the top to ensure that I would lay all the pieces in a straight line. I had a two-board spacer that I placed next to the first piece before gluing the spine. The spacer ensures that enough space is left between the two boards so that the hinge will bend.
Basically, I glue all the boards first onto the cloth, flip it over carefully, cover with clean newsprint, and then rub each covered board with my bone folder to ensure that there are no bubbles.
Then it’s a matter of trimming the corners, and gluing down the turn-ins. This gluing usually starts with the head and tail. This is because you need to work the cloth into the hinges. Anyway, the corners are trimmed at about a 45° angle leaving a board thickness between the cut and the boards.
This board thickness is needed to cover the corner neatly without creating too much thickness at the corners.
As the cloth is folded over the hinges, it’s important to use a bone folder to work it into the hinge. Also, I learned to try and pinch the corner triangle in slightly so that I wouldn’t create a really sharp corner. Pinching it in rounds the corner slightly and looks a lot nicer.
Depending upon the project the next step is either applying the hinge or filling in the case. Filling in the case simply means using additional bookcloth to cover the visible board. I can’t remember why this is important. Hmmmm.
So for this project, I applied a hinge. The hinge cloth is cut so that there is about 2 inches of cloth on either side of the spine that will be adhered to the boards. I always mark where to lay the hinge on one of the boards. The height of the hinge is usually slightly shorter than the height of the case. Cloth frays so you don’t want to have it go right to the edge, plus leaving it slightly shorter gives it a neater appearance on the finished product. To glue the hinge, you begin by applying it to one board, cover it with newsprint, and use the bone folder to smooth it on the board and work it towards the first hinge. Then, the bone folder is used to really work the cloth into the hinge and so on. By the time I reach the second board, I usually find that it doesn’t lay quite as evenly as I hope across them. But, as long as there’s about 3/4 inch, I know that it will be okay.
Next is deciding how the box will close. For this, I used bone clasps. This meant putting a ribbon on the top to hold the clasp and shut the box, as well as putting ribbon on the bottom. Adding ribbon means chiseling the board. So, next up was creating a jig to decide where the closure would appear on the cover. This would then dictate where the holes would go on the bottom.
For the top, I had to chisel two holes because I needed to create a loop. For the bottom, only one hole was needed. It’s important to use a chisel that’s the same size as your ribbon so that the holes will be hidden by the ribbon.
Once the ribbon is threaded through and the length needed to close the box and hold the bone clasp in place is verified, the ribbon is trimmed. Then, I created channels in the board to hold the ribbon and glued them down with PVC.
After that I filled in the center of the uncovered board with spare bookcloth and glued the bottom to the box with mixture. This was then pressed.
I can’t remember if I left it overnight or for a half-hour or so. Longer is always better with pressing. It’s done to make sure that the boards adhere to each other and don’t warp. Barbara actually placed it in the press for me. She wanted to make sure that press was tight enough to ensure the boards would adhere, but not tight enough to collapse the wall of the tray.
The next step was gluing the spine to the tray and pressing it with a weight. After that was lining the cover and the base of the box. I chose to line the cover with cloth over board to give the top a neater look. The finished product turned out pretty well, I think.
