Dovetail box with curved sides and piston fit tray

Making a wedding gift for a friend, a dovetail box with lift-out tray and arched sides, with hand tools.
Channels referenced in the video:
/ davidbarronfurniture
/ robcosmancom
I'm no professional and I don't have anything to teach, this is just me, sharing my thoughts and my work. Join me as I'm learning fine woodworking!

[@Krishna-Govender]

It doesn't really matter whether the videos are "good" or "bad". I watch these purely for the therapeutic value. Seeing woodwork being done using hand tools at a slower pace is just so satisfying.

[@GillisBjork]

Awesome, happy to be able to provide then!

[@jlinkels]

A woodworking video without high-speed playback? No music? Is this youtube? Excellent, thank you so much!

[@seaweedandeatit]

WOW. That is stunning. Thank you for sharing it. Maybe one day I shall be that good. Thank you so much.

[@leewood729]

Wow. Amazed there was NO electrical equipment, just lots and lots of cool planers I wish I owned. My father had one of those hand cranked drills, wish I knew where it was now. Beautiful work I haven't a chance in hell of being able to do myself, but loved watching it come together.

[@GillisBjork]

Thanks! The number of planes only speed things up or make certain jobs easier, you can do anything with a single bench plane, saw and chisel!

[@leewood729]

@@GillisBjork Well... maybe YOU can do anything with a bench plane saw and chisel, but I think I still have a ways to go before I'm half as good at it as you are. :)

[@MauricioGoncalves.]

Great job! Greetings from Brazil.

[@GillisBjork]

Thank you!

[@abnormica]

Re-sawing such a wide board by hand gives me cold sweats! I'm going to have to give it a try myself.

[@lucanwoodcraft8775]

First time finding you, this is unreal, nice to see hand tools used the old school ways, rather than machine this machine that. top class work sir. also subbed for more great content.

[@GillisBjork]

Many thanks!

[@oih1969]

Great to have you back! I know too well about losing motivation...

[@GillisBjork]

Thank you, yeah it's a bummer!

[@josephpotterf9459]

Thanks Gillis , I am impressed and sure that David Barron would be too your skills are improving . Keep up the good work

[@GillisBjork]

Many many thanks!

[@stevejensen3471]

Incredible box and handtool work Gillis. A rec on the squeezeout - I always wait until it is semisolid and then pick it up with my 1/8th inch chisel. It comes right up and doesn't smear. Love that QWO - my fav! Merry Christmas 2023 :)

[@markhanson7079]

I want to say thanks for the great tip on using tape to mark the pins of the dovetails. I'm new at hand cut dovetails and have had trouble finding a technique that works for me. After watching this, I tried it and it worked great!! My first joint fit right together without any work on the pins to get the joint to fit. Thanks agin for showing that. BTW, your box looks great!!

[@GillisBjork]

Glad you found something helpful in the video! Thanks!

[@PeriodWoodworker]

Very nice box. Thank you for sharing with us, Steve

[@GillisBjork]

Thank you very much!

[@mrJanniekoen]

Great work Gillis!

[@GillisBjork]

Thank you!

[@augusthermann2421]

Nice to see you again👍

[@GillisBjork]

Cheers man!

[@andyoverall1951]

As a fellow wood worker I can really appreciate the quality of your work. It must have taken a lot of patience and time. Good result!

[@GillisBjork]

Many thanks! Yup, time and patience is kinda the most important part of woodworking!

[@robcauson4595]

Hi. I've just found you. This video is brilliant, the box is brilliant, your narrative style is brilliant. I'm really looking forward to going back through some of your older stuff. Cheers.

[@GillisBjork]

Many thanks! Don't judge my older stuff too harshly please! ;)

[@nickyork8901]

beautiful box

[@tommyroberts9889]

Glad your back!

[@GillisBjork]

Thanks, good to be back!

[@ianwalters3485]

Nice workmanship

[@GillisBjork]

Thank you very much!

[@davidmiddleton3511]

Absolutely amazing.❤❤❤

[@GillisBjork]

Thank you!

[@paphaju1]

Nice one, congrats. I think quality over quantity should he the goal in youtube videos and youre is a prime example of that. Hats off 🤙.

[@tuffymartinez]

Thank You Gillis...WOW!!!!...I think this is my third time watching and each time I catch something new. As a life long machinist my one negative focus were the store purchased hinges. Please don't misunderstand. Your construction was totally beautiful. In my past projects I would always make unique brass hinges that could never be purchased at a store and made for that particular project never to be made the same again. I do this because I have the machinery for making it and it is FUN! Please keep this in mind if in the future you have an idea for a unique hinge. Sketch out your requirements & run it past me. In my simi retired life I do have the free time and interest. Again your workmanship is quite enjoyable to watch to say the least!.... TM

[@GillisBjork]

That's such a cool offer, I'd absolutely love to use a unique hinge like that! Thank you for offering! And I agree about the store bought hinges I used here, they were the best I could find within the timeframe I had but they are definitely flimsy. I don't have anything in the progress at the moment needing hardware, but if you want, you can send me an email so I know how to reach you :)

[@Rikiiiiiii]

Just amazing ! Good (hand) work !

[@GillisBjork]

Thanks!

[@johningram9700]

Great work! You character really shines through in your videos more than any curly maple ever could. God Bless!

[@HandToolWoodGuy]

Nice to see you back!

[@GillisBjork]

Cheers, good to be back!

[@Heseblesens]

Just beautiful...

[@GillisBjork]

Thank you!

[@onehandedmaker]

Hi Gillis, I just found your channel and have subscribed. Love the box build and your handtool work. Regards James One Handed Maker

[@seanflanagan2441]

Inspiring, and your commentary is very helpful. Thank you for putting in so much effort to document the project, and I am very grateful that you have shared this. Bless you, sir!

[@GillisBjork]

Big thanks, happy to hear that!

[@dietermuller3486]

Eine sehr schöne Übungsarbeit.

[@rattlejake0422]

It is a CRIME you have less than 10K followers here, Gillis. Your work is exemplary and your videos are a treat to watch. You've certainly earned at least one more in me with this build. Well done.

[@GillisBjork]

Thank you so much! 10k is starting to seem reachable which feels pretty insane to me! Glad to have you on board.

[@0ddSavant]

Very nice work. The dovetails and curved sides look amazing. Cheers!

[@GillisBjork]

Thank you so much!

[@whittysworkshop982]

The box looks VERY nice 😁 the fit you got on the tray was spectacular, so satisfying watching it slide down on a cushion of air 🤙

[@GillisBjork]

Thank you very much! Yeah that felt good :)

[@johnkirwan762]

Great job, I like the way you approached the tray bottom! I've used a combination plane to run a stopped groove many times btw- it's a bit fiddly and you need to still use a chisel to finish the ends/create the stop. But it goes fast

[@GillisBjork]

Thanks! Yeah it sounds doable, might have been faster!

[@russellfranken3662]

No need to apologize. Life gets in the way of a lot of things. We wait and watch because you are so talented. Keep them coming whenever that is.

[@GillisBjork]

Cheers for the encouraging words!

[@johnwalsh6844]

It looks great ! Nice job.

[@GillisBjork]

Many thanks!

[@walterrider9600]

thank you

[@whaustin]

Thank you so much for sharing your wonderfully skillfull work! It is very nice to see a craftsman work completely by hand. Do you give lessons on sharpening your saws, I am amazed at what you can accomplish with a ripsaw, really excellent work!

[@GillisBjork]

Thanks! I don't really think of my videos as lessons, as I'm self taught and not a professional. But it could happen in the future :)

[@mattedwards4533]

I have a woodworking shop with a full compliment of stationary wood working machines and I dare say it would be dificult for me to turn out a master piece like yours. I have been in the trade for 50 years. You did an excellent job!

[@GillisBjork]

Many thanks! Machines have their strengths for sure, but seem to me like they are best for production runs with many copies of each component, and maybe less convenient for one-off jobs?

[@jimneely4527]

Very nice work and excellent choice of woods to highlight your work. Thanks for sharing.

[@GillisBjork]

Thank you very much!

[@giuseppedeepakbentihandtoo3809]

Gillis you are a real craftsman, this what handmade is to me. Well done!! Bravissimo!!😀😀

[@GillisBjork]

Many thanks! I appreciate the support!

[@cafecybernz]

Very nice seeing you again, missed your videos. As Martin Schmutz said, you are indeed an outstanding hero in the woodworking world. The quality of the craftsmanship, the steady video recording without mad cuts, the crisp audio befitting your calm voice (a touch of rain on the roof: nice) without forgetting the total absence of power tools, all of these elements elevate this project to pure KZbin bliss. And resawing wood planks entirely by hand?! That is sheer dedication. Respect. Really hoping to see more projects in the future.

[@GillisBjork]

Massive thanks, super appreciated! I like that you noticed the rain, that was a moment I really enjoyed myself :)

[@1954JDR]

Fantastic work. I love the fact that you use only hand tools. My uncle was that type of craftsman. He made beautiful items.

[@GillisBjork]

Thank you! It's a fun way to work!

[@chriscomertn]

What an outstanding project! Those rounded dove tail sides blow me away.

[@GillisBjork]

Thank you! They were not too hard to make, looks fancier than it is! :)

[@pinkiebrain7597]

A 👍 for the algorithm and of course your work. 😊

[@GillisBjork]

Thanks, appreciated!

[@gholmes182]

Outstanding

[@bernardpots5851]

Helt fantastisk!

[@GillisBjork]

Tack så mycket!

[@claudeelliott3993]

Really interesting video! I don't have the patience or skills to do something like this but I certainly enjoy watching you do your magic! Thank you and keep up the great work.

[@GillisBjork]

Thank you very much!

[@Nono-hk3is]

Beautiful

[@GillisBjork]

Thank you!

[@mmd1957]

Another excellent piece of work.

[@GillisBjork]

Many thanks!

[@jackdelancey248]

Nice!

[@TomDanaher]

Good stuff.

[@GillisBjork]

Thanks!

[@Mat-q5z]

To me, you are the outstanding hero on woodworking, lead of the pack due to the most authentic craftsmenship. I wish you great satisfaction on giong on that route. Thank you for sharing your work!

[@GillisBjork]

Incredibly generous words, thank you very much!

[@Rich32262]

So inspiring. I have used Rob Cosman's dovetail technique but that dovetail alignment board you have makes it even easier. For us aspiring woodworkers, I learned quite a bit in this video. Thank you for taking the time.

[@GillisBjork]

It's a pretty neat jig! Thank you!

[@4Truth4All]

What a wonderful project. Your approach and methods are refreshing and inspiring. Keep up the good work!

[@GillisBjork]

Many thanks!

[@bertRaven1]

nice work, well done.

[@GillisBjork]

Thank you!

[@artfgs5713]

Hola... Felicidades!!! Mi más sincero reconocimiento a tu trabajo, el cual es una verdadera maravilla, realizado con maestría y cariño por un trabajo realizado a la vieja usanza... Además tu vídeo es elegante al igual que tu trabajo... Te Felicito de nuevo por este proyecto con un resultado espectacular... Felicidades!!! Saludos.

[@GillisBjork]

Thank you very much!

[@jcsrst]

Wow! Super beautiful! Such skill with all your hand tools too. Love the sound of a sharp tool!

[@GillisBjork]

Thank you very much!

[@bigal3189]

I've watched most of your videos and I have to say the progression of your skills is brilliant. Thanks for the awesome videos and keep them coming haha

[@GillisBjork]

Thank you very much, I'm happy that you can see progression!

[@stephaniek-s994]

What a touching wedding gift. I hope you share this video with the new married couple so they can see all the hard work that you put into it. Awesome heirloom piece. Thanks as always for your explanation.😉👍👍

[@GillisBjork]

Thank you very much! They found it :)

[@WoodfulProjects]

Lots of good hand working techniques. Loved the build. Well done.

[@GillisBjork]

Thank you very much!

[@johanflodkvist80]

Inspirerande!

[@GillisBjork]

Tack, roligt att höra!

[@Ababa900]

Beautiful video! Would love to see more Beautiful result, you're truly an inspiration Beautiful wood too!!

[@GillisBjork]

Thanks a bunch! Yeah I was lucky to have these pieces, the box would fall flat without them!

[@Ababa900]

I think that the design that you put into it was as much as important!

[@billbris]

I have no words, except Thank You.

[@GillisBjork]

It was my pleasure!

[@davidadaur5163]

Gillis: That is a beautiful box. Thank you for sharing your design and your outstanding skill with handtools. David Adair

[@GillisBjork]

Thank you very much, David!

[@nicolajhansen7232]

Smukt udført. Og sikke en tålmodighed 👍👌

[@GillisBjork]

Tack så mycket!

[@MCsCreations]

Amazing work, dude! Fantastic looking box! 😃 I loved the way you made it! Stay safe there with your family! 🖖😊

[@GillisBjork]

Many thanks!

[@MikeAG333]

Great video. Love the process, but I'm not keen on contrasting timbers, so the finished box isn't my favourite. You made most of the box exactly how I would have done, although I might have clamped a batten in place to guide the long cut when taking off the lid, and I am sure I wouldn't have planed out from the walnut across the dovetails for risk of breaking them out. I have also finally given up on Osmo after years of frustration. Did you consider making the tray base first and them using that to ensure the sides stayed square when clamping? I've now subscribed, and will work my way through your back catalogue of videos. I hope your wobbly bench and weak vice don't annoy me too much!!! Your video style is precisely how I like them.......gentle, laid-back, matter-of-fact, and letting the woodwork dominate rather than music or some shouty presentation style.

[@GillisBjork]

Thank you for your thoughts! A batten to saw against is a good idea, and you're absolutely right about planing out across tails. It can be done with a sharp blade, skewed angle and shallow depth of cut, but I don't know why I took the unnecessary risk. Making the tray base first would work too, but I figured it would be easier to install it afterwards because of the extra pieces with the groove, which would be a lot to juggle in a single glueup. Not sure what you mean by wobbly bench and weak vice, but glad you like the video style, I hope you enjoy the rest :)

[@romannoble]

I'm so happy you made a new video. I think I can say there is a whole group of us that missed you. I can tell you have gained quite a bit of experience. The workman ship is superb. Also, your video style has a captive story telling appeal. Keep it up. Glad to see you're doing great stuff!

[@GillisBjork]

Thank you so much! I feel very lucky to have that group :)

[@rollingstone3017]

Super nice build. Innovative way to cut those dovetails on a curve!! We should name the method after you. 😁

[@GillisBjork]

Thank you! Haha well, it was just what seemed to be a sensible way to do it ;)

[@rollingstone3017]

@@GillisBjork Let’s call it the Bjork Method 🤔

[@sqol]

I love the detail of the “split” dovetail that spans the box and the lid, and the finish looks great.

[@GillisBjork]

Thank you very much!

[@heyimamaker]

Looks amazing, I love the spalted wood!

[@GillisBjork]

Thanks!

[@ronhochhalter3491]

Your skills are very admirable, I thoroughly enjoyed this video. I really like the design of this project. Thank you for sharing.

[@GillisBjork]

Many thanks, glad you enjoyed!

[@franks122]

Thanks for sharing, I love hand tool videos. I use had tools myself.

[@GillisBjork]

Awesome, thanks for watching!

[@TSolderman]

Supernice work as allways. Seems like if santa brought you a alternator and a bandsaw for Christmas you would have mor time for more projects 😊

[@GillisBjork]

Thank you! Yes, that sounds like a very good idea hahaha

[@jcfetz]

Fantastic craftsmanship as always! I really enjoy your videos and explanations. Thank you!

[@GillisBjork]

Thank you very much!

[@shawnataylor7998]

Very nice box. Thanks for sharing your craft.

[@GillisBjork]

Thank you very much!

[@thomnash3548]

Very nice. Keep up the excellent work!

[@markevans3248]

A stunning design and skill fully executed a pleasure to watch. Thank you.

[@GillisBjork]

Thank you so much!

[@dalejones4186]

Just found your channel. Absolutely enjoy watching videos wit people who are extremely good using hand tools. Turned out gorgeous .

[@GillisBjork]

Welcome to the channel and thank you very much!

[@planespeaking]

Such skills. Very envious. Any particular chisels you favour? Looking for a decent set. Hope you post again.

[@GillisBjork]

Thank you! I use a random fleamarket assortment, mostly vintage E. A. Berg, but not really tried enough different brands to be able to give a recommendation.

[@jamesnderry]

Fantastic video, absolutely beautiful box, well done!

[@GillisBjork]

Thank you very much!

[@RGRGJKK]

Pura vida Gillis calidad de trabajo y casi todo hecho a mano mis respetos son técnicas que se pierden porque se entiende que tiempo ⏲️=money so with modern jigs and power tools you save money but if someone had time try and learn how to do it with hand tools in the ways hand tools techniques will not become extinct.pura vida Gillis and guys

[@andrewbrown8148]

Beautiful piece~!! Love the design and the wood selection.

[@GillisBjork]

Thank you so much!

[@hassanal-mosawi4235]

Thanks for sharing those tips and the make!

[@GillisBjork]

Thanks for your support!

[@chuckpremer3111]

You were missed, wish you better health and a better mic. As always, outstanding work.

[@GillisBjork]

Many thanks! Not getting a new mic again soon though I'm afraid, I hope this one will suffice!

[@pettere8429]

Trevligt med en ny video! Håller på med ett strykmått inspirerat av det du gjorde för några år sedan. Gillar excenterkamlåsningen till armen.

[@GillisBjork]

Åh ser man på! Kul att höra, glad att du fick inspiration!

[@victorlundin5075]

Best gift ever!

[@dpmeyer4867]

nice

[@GillisBjork]

Thank you!

[@gbwildlifeuk8269]

Lovely job 👍👍👍👍

[@GillisBjork]

Cheers!

[@geoffroypeyssonneaux8035]

Nicely done !

[@GillisBjork]

Thank you!

[@IvorPuddifant]

An original design that turned out beautifully. How many hours would you say this took?

[@GillisBjork]

Many thanks! Assuming I didn't forget to write down any, it took 51 hours.

[@congruewoodworks1474]

Fantastic build and incredible use of your tools! Subbed.

[@GillisBjork]

Thank you so much!

[@docrumpel1260]

I have missed your videos very much. I was afraid that you would not publish any more. But now the joy is even greater! This has become a very nice box! Perfect fit and that only with hand tools. The contrasts are already very extreme, but I like it very much. As always, my hat is off to you! What kind of wood is the lid? I think I overheard that and I've never worked with wood like that.

[@GillisBjork]

Sorry it took so long, Doc! I very much intend to keep publishing :) Many thanks for the kind words. The lid is spalted beech; beech is a pretty common tree in Europe at least (unsure about rest of the world) but usually gives quite dull looking lumber. But when spalted, it becomes one of my favorites. Real "diamond in the rough" kind of situation with that species!

[@darkosimic86]

Hej Gillis! Välkommen tillbaka! Hoppas du inte låter oss vänta så länge på din nästa video! Underbar video som vanligt :)

[@GillisBjork]

Tack så mycket! Ska försöka vara snabbare nästa gång :)

[@williamcowan5296]

Gillis…I’ve been wood working for along time and you have amazing master skills. How many hours did it take? Thank you for showing us your video and look forward to watching more..Bill

[@GillisBjork]

Thank you so much! I put about 50 hours in this one.

[@pmewUK]

Love it. Voice sounds fine to me and the audio was good all round. A very satisfying viewing experience. I've been thinking about obtaining a fillister plane, you spoke briefly there that you love that Stanley. If you get the chance, could you explain why you like it so much?

[@GillisBjork]

Thank you, glad to hear it! Yeah I think the Stanley 45 is awesome. It gives so many options and finetuned adjustability, which in the case of grooves is very useful in my opinion, as I often want a very specific fence offset, groove width, or depth of cut, to match a dovetail location or something like that. Dedicated wooden planes filling all the same roles would take a huge amount of space!

[@pmewUK]

Available space - that is a fair point and quite a big seller for me. My workspace is pretty small, specifically its a narrow 7 foot wide workshop so the versatility sounds very appealing. Thanks. Love your work by the way, its very inspiring.

[@GillisBjork]

@@pmewUK Yep, an important factor for me too! Many thanks!

[@con-f-use]

Those are some fancy damn clamps at 1:12. Is there a story behind these?

[@GillisBjork]

not really, unless "bought them from a store" counts as a story ;) They are from Dubuque clamp works

[@brigetteanderson-atkins1128]

I hope you are feeling better. It was worth the wait! Is there a reason you did not shape the box prior to cutting the lid off?

[@GillisBjork]

Many thanks! Yes indeed, it was to make sure the lid would align when closed. If I shaped the sides first, any misalignment after the hinges are installed would affect the curve.

[@brigetteanderson-atkins1128]

@@GillisBjork Thank you for the explanation.

[@taosclark]

How do you manage to get a saw you can sharpen and use that well for ripping? I'm looking everywhere but I can't seem to find one

[@GillisBjork]

Lots of flea markets and keeping a close eye on local auction websites. I've started looking for brass bolts/nuts and wooden handles, as that signifies age (not a guarantee though, of course), and don't be afraid of rust, that's easy to remove for a tool that'll last lifetimes. If it comes with rip or crosscut teeth is not the biggest deal, you can change it when sharpening, so tooth/gullet size is more important in my opinion.

[@abbbee8918]

What training have you had? You’ve obviously watched a lot of KZbin!

[@GillisBjork]

Watching youtube, reading books and building things :)