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Another Death Box (Read 2137 times)
J_Rock
Ex Member



Another Death Box
02/20/06 at 05:42:12
 
I promised someone I would start a thread on how to cover a box in fabric, so here it is.

No pics yet, tomorrow I promise.

First Off, I start by making the box, I have done so many of these it takes me about 45 minutes with an airnailer and a table saw.

I made this box out of Maple Vennered Fiber Core Plywood.  Densest scrape I had around(well, in quantities to build a box.)

After making the box I went out and purchased 1.33 yards of fabric.  This gives plenty left over and is about the least I can purchase and not have to squeeze my brain to fit the pieces.  

I purchased leather this time around.

I wanted to do designs on the side of this box so, Next I bought some 1/8 inch foam and cut designs out of making sure I held the blade at 45 degrees to the surface.  

I then glued these designs to the box using spray adhesive.
3M 77, or similar strong fabric/multiuse adhesives work.  (I would use real upholstery contact cement but I have no access to it.)

With my designs carefully mounted in the areas of the box I wanted them, I than cut out my fabric.  I like to start big and trim the fabric down, so I cut pieces roughly 2-3 inches larger in each dimension.

Next I spray the fabric and the box with adhesive.  A good coating is needed, but 3M 77 works best with a light to medium coat, not too heavy or stuff doesn't dry.

With designs on the side of the box, things become a little difficult.  I lay the fabric onto the desing first and work my way to the edges of the box smoothing everything out.  Its best to have something smooth and small to roll creases and wrinkles out(I use a sharpy marker, no idea why).

After the glue drys for 15-20 minutes a side, I cut the excess fabric off.  On this box, I trimmed to 1/4 inch of the edges because I planed on trim.  

If you wish, you can learn to sew and sew all 4 sides of the box together slightly smaller than the actuall box.  This is then pulled down the sides and smoothed out.  It ill allow only 4 nice seams (or one depending on how you lay out) at the corners.  The slightly smaller requirement is for a tight fit with no wrinkles.
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J_Rock
Ex Member



Re: Another Death Box
Reply #1 - 02/20/06 at 05:47:37
 
With the side edges trimmed, I fold the top and bottom edge fabric over to the inside of the box.  I then stable this excess to the inside to ensure more tight fitting.

For the tops of the boxes I cut a square 3 inches larger.  I then lay this square out and spray the fabric and wood with adhesive, just like before.

I then stretch the fabric around the edge and stable, working from the center of each edge to the corners. I am careful to leave 1-2 inches at each corner.

With the edges stable down and the corners needing finishing, i fold the fabric into whatever shape is necessary to get a nice finished edge.  I then stable this final fold down.

Trim off excess, and bingo you are done.

I make all my boxes to fit snug when bare.  Then when the fabric is tightly wrapped, I get a very secure fit.  This latest box actually requires a hammer to pound the top and bottom in, and can be played with no other fastener holding the covers on.

Pics soon!
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Adrian D.
Ex Member



Re: Another Death Box
Reply #2 - 02/20/06 at 12:24:41
 
thanks a lot J-Rock
i have a friend who made a leather backpack for me. he knows a thing or two about working with leather.
it just didn't cross my mind that it would be nice to build a leather 'sock' for the box.
i have some cow leather, with fur on it, somewhere in the garage... although it's old, the fur is still firmly attached. i plan on building another db-10 and covering the box in that material. i hope it'll look good.
thanks again for the thread. just don't forget the pics.
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J_Rock
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Re: Another Death Box
Reply #3 - 02/22/06 at 02:56:48
 
Well, pics are late but most things are with me

Here we go though:

This is a pic of the finished box:
http://img.photobucket.com/albums/v652/J_rock777/FullView.jpg

This is the Finished Top and Bottom Pieces:
http://img.photobucket.com/albums/v652/J_rock777/TopBottom.jpg

The side with a rose:
http://img.photobucket.com/albums/v652/J_rock777/Rose.jpg

The side with two Palm Trees and a Sun:
http://img.photobucket.com/albums/v652/J_rock777/PalmTrees.jpg

The side with a fairy:
http://img.photobucket.com/albums/v652/J_rock777/Fairy.jpg

The sub inside:
http://img.photobucket.com/albums/v652/J_rock777/Sub.jpg

This is how the tops and bottoms were folded:
http://img.photobucket.com/albums/v652/J_rock777/TopBottomWork.jpg

This is how the curved port cut was covered:
http://img.photobucket.com/albums/v652/J_rock777/PortReverse.jpg

And a final closeup from the front for the Port:
http://img.photobucket.com/albums/v652/J_rock777/8996a9f7.jpg

Notice the girly designs, well box is a gift for my Girlfriend and she absolutely loves it.  The side with the port is not pictured because it says here entire name in Grafitti writing.  Her first name though, as you can see is Kate.

Any questions on anything I am willing to help 24/7 basically.
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« Last Edit: 02/22/06 at 02:59:28 by j_rock777 »  
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Adrian D.
Ex Member



Re: Another Death Box
Reply #4 - 02/22/06 at 11:49:42
 
it looks great. now i see that each panel was separetly covered. that was the only thing that i was uncertain of.
good idea about those small pieces of mdf on the bottom lid, to ensure the seal. that's something i'll use in my next db-10 build.
thanks for the pics. and for the tutorial
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