Advice for carving boxes

[Jeremy L.]

Yesterday I tried my hand at shaping one of my boxes for the first time. I loved it, couldn't stop until it was done and had some linseed oil rubbed on it. I used a 4" angle grinder with 36 grit wheel and a random orbit. This worked, obviously, but it got me interested in finding a better/easier/faster way.

The 36 grit wheel started burning the walnut after awhile, I guess resin buildup or something. I burned through a lot of orbital sander disks, the edges especially trying to sand into curves. It also started eating up the platen on my expensive Bosch sander. As I was experimenting, I wanted to make deeper waves and shapes, but quickly realized I'd never be able to sand to the finish I desired if I did.

So please, help me explore options as to what carving and sanding solutions would help me the most, and give me some more room to experiment without worrying about how I'll finish the end result. Maybe a "better than what you have" option then a few upper tier options? A better, best and then besterest ( I know that's not a word) type thing.

[davidinsarasota]

Beautiful box, I can see why you are enthusiastic.

There are lots of options for angle grinders as well as additional powertools such as die grinders and flex shaft machines such as Foredom and others.

Here is a link to KAT's Holey Galahad, which would have been a better option to start with than a sanding disc.
Holey Galahad Sanders | King Arthur's Tools

Here is one for Kutzall:
Dish Wheels | Products | Kutzall | Oliver Carbide Products

I have not used the discs, but do use the Lancelot on my side grinder for roughing out.

Don Sexton is our resident guru on anglegrinders and such here is a link to a recent post by him. Click his name at the top of his post and select 'find all posts by' in the drop down. Have fun.
More grinder info

[Claude]

Nice box!

Claude

[Jeremy L.]

Thank you, I ordered a Kutzall wheel to give it a shot.

[davidinsarasota]

Sounds good Jeremy. Let me know how you like it, maybe I need one.

[Pappajohn]

I really like the box. You have accomplished what I have been wanting to do for quite some time, that is, shape deep grooves in a wooden box. I just never had the nerve to try it with my 4" angle grinder. I'm not really sure of your question since it seems that you already have both the shaping and the sanding functions pretty down pat. If you are looking to go deeper with the waves, I suggest the King Arthur wheels as mentioned above. They will cost you about $50 but they cut through better than a 36 grit wheel. However, I sort of like the waves at the depth you show in the photos. If you are looking for quick and easy sanding, I would use a flexible cylindrical sander that is used with a Dremel or Foredom power carvers. They come in various sizes and can be found in most carving supply catalogs. You attach whatever grit sandpaper you want. I've been using then to sand carvings for years. Good luck!

[brent]

Damn (fantastic) work!!

[Tommy Taylor]

Jeremy I think it's a beautiful box.I don't know if this might be what would help but I did the spiral rope with a Dremel tool and the round sanding attachment.It was cedar though which I don't think is as hard as the walnut so not sure which works better especially since I haven't used what you did.You did a great job.

[SeaLeveler]

Awesome box with some equally beautiful wood.
Tony