Fly Fishing Boxes From Rough Lumber

The process behind creating 37 fly fishing boxes from 5 pieces of rough cut, air-dried lumber.

[@Steve-rr3gc]

Very nice workmanship!

[@conefurnishings]

Thank you!

[@grassrootsinab]

Great project! where did you source the fly foam from?

[@conefurnishings]

Thanks! The client provided the foam, but he had found it on Amazon. I got asked to do a few more of these recently, and the Amazon seller reposted after the item had been unavailable for some time. FYI if you do purchase, the adhesive back is not great, but some spray adhesive does the trick! I’ll include the link here: “Fly Foam Ripple (Pack of 10), Peel and Stick, 8 1/4" L x 4 1/4" W x 1/4" Thick, Off White Color” www.amazon.com/dp/B01EEBZZ32/ref=cm_sw_r_cp_api_glt_fabc_YTRXMPMSPET9Q999HK94?_encoding=UTF8&psc=1

[@matthewforgione9468]

Great video. What kind of hinge did you use? thanks

[@conefurnishings]

Thanks for watching! I found the hinges through Amazon. I have ordered from a couple different sellers since making this batch, and they all seem to be the same 10mm hinges.

[@mdaley3102]

Very nice. What a great way to use “scrap” lumber. Where did you find the foam material. I’ve searched Amazon and it just comes up with the fly boxes or inserts for a particular box. Did you consider putting the foam on both sides. Thanks

[@conefurnishings]

Thank you! I worked with a specific group for this and they requested foam on only the one side. The specific foam I used shows up on Amazon occasionally, but doesn’t seem to be regularly stocked. I got a few more orders for these later on and had a hard time locating more of the foam.

[@conefurnishings]

Actually here is the link: BHD (Pack of 12) Medium Fly Foam... www.amazon.com/dp/B0775ZD9PT?ref=ppx_pop_mob_ap_share

[@alexhenderson6549]

Great project and love the finished box. Can I ask where you got your foam pads?

[@conefurnishings]

Thanks! The foam was from an Amazon seller. They actually have it relisted right now which doesn’t seem to happen often. Here is the link: www.amazon.com/dp/B01EEBZZ32/ref=cm_sw_r_cp_api_glt_fabc_YTRXMPMSPET9Q999HK94?_encoding=UTF8&psc=1 Magnets were just bought locally at Menards. I had some from Amazon, but they didn’t have quite the same pull.

[@coyfish1197]

What hinges did you use? Great build

[@conefurnishings]

Just used some 10mm brass barrel hinges. I believe you can find them on Rockler, or even Amazon!

[@reelisticoutdoors4358]

where did you order the foam from ?

[@tld5150]

Awesome boxes! What were the final dimensions? Yours looks bigger than most I'm seeing online and I like the larger size

[@knothead5]

Good question. It would be good to visit stores and measure the pockets inside and outside of waders and fly fishing vests.

[@conefurnishings]

5 7/8” x 4 3/8” - we based the size off the foam because the customer preferred that specific foam pad.

[@adamraymakers8295]

Out of curiosity, where did you get the magnets and foam for the boxes?

[@conefurnishings]

For the magnets we tried some from Menards, and some from Amazon. They both held quite strong with two contact points on the boxes. The foam was provided by the client, and I am actually in process of attempting to find the same product for more of these boxes! Wish I had a better answer for that foam.

[@adamraymakers8295]

@@conefurnishings Thanks for that! If you do find a solution to the foam problem (I've seen other builders mention it as well), it'd be great if you could post it!

[@conefurnishings]

@@adamraymakers8295 I will post if I’m able to find anything!

[@conefurnishings]

@@adamraymakers8295 so the Amazon seller did post the exact size of foam again, and I purchased some for a few more boxes like this. I’m sharing a link from the same seller, but a slightly different size which is all they have available as of now. “Fly Foam Ripple (Pack of 10), Peel and Stick, 8 1/4" L x 4 1/4" W x 1/4" Thick, Off White Color” www.amazon.com/dp/B01EEBZZ32/ref=cm_sw_r_cp_api_glt_fabc_YTRXMPMSPET9Q999HK94?_encoding=UTF8&psc=1

[@adamraymakers8295]

@@conefurnishings Thats awesome. Looks like they might be sold out already but I'll keep an eye out... thanks!

[@gerryfelix5948]

Great video. If I may, what is the thickness of each piece?

[@conefurnishings]

Thanks! The top and bottom of each fly box is around 1” thick with a 1/2” recess. The hardwood ones were more like 7/8”

[@gerryfelix5948]

@@conefurnishings thanks for the quick reply. Next for me is to make copy of your jig for routing. I plan on making the boxes out of cherry and limiting the thickness to 3/4 inch. Wish me luck.

[@conefurnishings]

Good luck with everything! On the third batch of these I made just last month, I added a 1/4” spacer to thicken the area where the barrel hinge goes. Just to make sure I avoided any possible weakness in that area. I had a couple crack near the end grain which is quite frustrating at that point in the process.

[@gerryfelix5948]

@@conefurnishings thx for the heads up. One last question what router bit did you use?

[@conefurnishings]

Just used a 3/4” straight bit, but I’ve heard spiral bits could be a better option, I just didn’t have one.

[@robslifting4life]

What is that reclaimed Elm?

[@conefurnishings]

I would say you’re correct. It’s in line with other photos of spalted elm. Client provided the lumber, and didn’t know for sure!

[@jjns3991624]

Pretty cool but for practical purposes the box needs to open flat. I can’t deal with a box if it only opens half way.

[@conefurnishings]

Thanks! Those barrel hinges do allow the top to open all the way flat if placed perfectly. In our case, the client wasn’t concerned so we essentially centered them in the space we had.