Thinking inside the box
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I know architects like to "think outside the box," but sometimes it is necessary to go the other direction.
I was recently invited to participate in a Vietnam combat photo exhibit at Cardinal Stritch University in Milwaukee, Wisconsin. I needed a way to send 10 matted 16x20 prints and make sure they arrive intact. I needed a sturdy box that was shock buffered on the inside and needed to pay special attention to the corners of the foam core boards which are often destroyed before they even leave the art supply store. So the corners are just floated in open space.
I had some double density foam on the floor of my garage that was eventually destined for the trash. I cut my plywood on the table saw and debated also cutting the foam the same way. I was afraid the saw would suck the foam into the saw and drag me with it. Luckily this foam cut like a dream. The foam has two densities. the first layer compresses easily and the second is stiffer. And even if the stiff foam ever had to come into play the lighter foam would have already decelerated the contents.
So this is just a humble box but the virtual planning and test fitting made the detailing of the project much easier in the real world.
The ultimate came when I took the box to UPS for shipment and some random person complemented on the construction, "Nice box." The next question was, "What's in it." When I said, "combat photos" I suddenly had seven or eight people staring at me.
The render was 12hr27min47sec in Twilight render with Metropolis Light Transfer and bi directional path tracing.
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Very nice render. No flies on the box, either. I salute your ingenuity. I notice you used special screws and- what? cup washers?
For overkill, I could recommend internally threaded inserts to receive long shank hex headed cap screws
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I can do flies if you want them. Yes, those were cup washers to spread the force since the holes are so close to the edge of the thin ply. Are the inserts knurled on the outside and then glued into their holes? Thanks for the comments.
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Well done render!
Oooh, drilling edge on into thin plywood. Very tricky. Did you make pilot holes?
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Oops.
I lost this thread and forgot to reply.
Yes, one type of insert is predrilled and tapped in with glue. Another type is coarsely threaded on the outside to be screwed in. Helps to have glue for this one too.
But Bryan is right. Gotta be careful. -
The plywood that was edge drilled was 3/4". The bottom 1/4" inch panel was glued and nailed. It was the removable top that concerned me where I had to within (not into)3/8 of the edge of the 1.4" thick top. But the box was over engineered and everything arrived at the gallery intact. Maybe I should have been a nuclear engineer.
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Yeah, that's the old "belt and suspenders" philosophy. In USA, suspenders means those over the shoulder straps designed to hold mens' trousers up. The belt is for looks.
Good job, Roger. My best wishes.
mitcorb -
Nice!
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