1. Process begins with a rough board of Walnut or Cherry being planed to proper thickness.
2. After each board is ripped on the table saw to size, the mitre joints are cut on a manual frame chopper.
3. Sheets of burl are selected to create the top of the boxes.
4. Veneer is cut and matched to make what is called a "bookmatch." This is laminated to a furniture grade particle board which is very stable.
5. The burl top is squared up and the wood is mitred and glued to it, which creates the top of the box.
6. The bottom of the box is mitred and glued as an exact fit to the top.
7. When dry, the box is sanded on a stationary sander, hinges installed, and hand sanded with two different grit sandpapers.
8. A four to six day finishing process makes the completed box and after having made hundreds of boxes, " I still get excited when the first coat of lacquer is hand brushed and the beautiful character of the burl and hardwood come to life."