Build It | Hawaiian Mango Keepsake Box

Creating a beautiful, handcrafted keepsake box is a rewarding woodworking project that combines functionality with artistry. In this guide, we explore how to construct a stunning Hawaiian mango keepsake box, perfect for storing precious mementos or as a thoughtful gift. This Old House expert Tom Silva works with Hawaiian woodworker Joe Jossem (“J.J.”) to demonstrate the process, showcasing the unique beauty of Hawaiian curly mango lumber and innovative finishing techniques.

*Assuming the wood used is not salvaged. Unless otherwise noted, costs in this article reflect an average of prices that our team found from hardware stores like Lowes and Home Depot, and on Amazon.com.

Selecting and Preparing the Hawaiian Mango Wood

The choice of wood is important for crafting a keepsake box that’s both beautiful and durable. Hawaiian curly mango lumber offers a distinctive grain pattern and rich color that makes each box unique.

Sourcing Hawaiian Mango Wood

Hawaiian mango wood is often sourced from salvage companies or tree services. This sustainable approach ensures that fallen or removed trees are put to good use. When selecting mango wood:

• Look for pieces with interesting grain patterns
• Choose wood that has been properly dried
• Consider the color variations within the wood

Drying and Milling the Wood

Proper preparation of the wood is essential for creating a high-quality keepsake box. The process entails:

• Air-drying the wood for approximately two years
• Aiming for a moisture content of about 14%
• Milling the lumber to the desired dimensions

Once the wood reaches the appropriate moisture level, it’s ready for milling. This process involves running the lumber through a wide-belt sander to level it, then using a jointer to create a straight edge. Finally, the wood is cut to size on a table saw.

Cutting and Shaping the Keepsake Box Components

With the wood prepared, it’s time to cut and shape the individual components of the keepsake box.

Create the Box Sides

The sides of the box are typically cut from a single piece of wood to ensure grain continuity. To create the box sides:

1. Cut the dimensioned lumber into pieces about 3/8″ thick on the band saw.
2. Run the pieces through a wide belt sander for a smooth finish.
3. Cut a dado on the table saw to hold the bottom in place.

Prepare the Box Bottom

For the bottom of the box, a thin piece of koa wood is often used. This contrasting wood adds visual interest to the interior of the box. The bottom piece should be cut to fit snugly within the dado of the box sides.

Finishing the Keepsake Box Interior

Applying a finish to the interior of the box before assembly ensures a smooth, professional result.

Sand the Interior

Begin by sanding the interior surfaces of the box sides:

1. Start with 220-grit sandpaper.
2. Progress through increasingly fine grits.
3. Finish with 1200-grit sandpaper for an ultra-smooth surface.

Apply the Interior Finish

J.J. demonstrates an innovative finishing technique using polyurethane glue:

1. Apply a few drops of polyurethane glue to the wood surface.
2. Work the glue into the wood grain using a finishing rag.
3. Wipe down the surface immediately after application.
4. Continue wiping every 10-15 minutes until the glue has cured.

After the glue has cured, sand the surface again with 1200-grit sandpaper. Finally, apply a coat of paste wax for the final interior finish.

Assembling the Keepsake Box

With the interior finished, it’s time to assemble the box components.

Miter the Corners

To create seamless corners that showcase the continuous grain pattern:

1. Cut the box sides to length on the table saw.
2. Miter the corners to 45 degrees.

Glue the Box Together

Use polyurethane glue to assemble the box:

1. Apply glue to the mitered edges.
2. Insert the koa wood bottom into the dado.
3. Use strap clamps to hold the miters true while the glue sets.

Allow the glue to dry for about an hour before proceeding to the next step.

Creating the Mango Wood Lid

The lid of the keepsake box is created from the top portion of the assembled box, ensuring a perfect grain match.

Cut the Lid

Once the glue has set:

1. Run the box through the table saw, removing the top third.
2. This separated portion will serve as the lid.

Add Splines

To reinforce the corners and add decorative detail:

1. Use a jig to hold the box and lid at 45 degrees.
2. Run them separately through the table saw to create spaces for splines.
3. Cut splines from Cuban mahogany scraps.
4. Glue the splines into place using polyurethane glue.

While the splines dry, run the box and lid through the wide belt sander to ensure everything is level.

Final Touches and Exterior Finish on Mango Wood

The last steps involve adding the finishing touches and applying the exterior finish.

Install Hinges

To attach the lid:

1. Drill two 5-mm holes on the box and lid for barrel hinges.
2. Cut a chamfer on the bottom and top of the lid where the hinge holes are to ensure smooth opening.
3. Install the barrel hinges using super glue to hold them in place.

Apply the Exterior Finish

For the exterior finish, use the same polyurethane glue technique as the interior:

1. Sand the exterior surfaces, progressing through grits up to 1200.
2. Apply polyurethane glue as a finish, working it into the grain.
3. Wipe down the surface periodically as it cures.
4. Once dry, apply a final coat of paste wax.

In the video, J.J. explains that this unique finishing method provides a beautiful, semi-gloss sheen that enhances the natural beauty of the mango wood.

Adding Feet and Lining to the Keepsake Box

To personalize the keepsake box even further, consider adding small details that make a big difference.

Add Feet

Small wooden feet can be attached to the bottom of the box. These feet can be made from leftover wood scraps and add a touch of elegance. To add feet:

1. Cut four small blocks of wood to the desired size.
2. Sand them smoothly.
3. Glue and screw the feet to the bottom corners of the box.

Add a Lining

A felt or fabric lining can protect the interior of the box and add a luxurious touch. To add a lining:

1. Measure the interior dimensions of the box.
2. Cut felt or fabric to fit snugly.
3. Secure the lining with fabric glue.

Personalized Engraving

Adding an engraved name or message to the keepsake box makes it extra special as a gift or personal treasure.

Engraving Techniques

Consider using a wood-burning tool or an engraving router to add personalization. Practice on scrap wood first to perfect your technique.

1. Choose a design or message.
2. Lightly sketch it onto the box with a pencil.
3. Carefully engrave over the sketch.

Our Conclusion

Crafting a Hawaiian mango keepsake box is a rewarding project that combines woodworking skills with artistic flair. The unique grain of the mango wood, coupled with innovative finishing techniques, results in a stunning piece that’s both functional and beautiful. With patience and attention to detail, you can create a truly one-of-a-kind keepsake box.

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