The Wood Hinge Box
DVD By Rob Cosman
Intricate boxes made with precious shop scraps are of endless fascination to woodworkers. Perhaps it is that so much is at stake in such a small projects; the design, joinery and execution must be flawless for it is all right there in your hands for up close inspection. If there is one thing that I enjoy as much as working in my own shop, it is watching another craftsman at work. In this one hour and forty minute DVD presentation, Rob Cosman demonstrates his considerable skill with hand tools and builds an exquisite wood hinge box in cherry and walnut with a virtually invisible wooden hinge.
The DVD begins right at the start with the stock preparation and then progresses along through every stage of the construction. Many woodworkers know of Rob Cosman
through his frequent appearances at wood shows and have come to regard him as a hand tools expert. It may come as a surprise to see him using power tools in this video, but he does, just like the rest of us. Rob shares his tips and tricks as the box progresses (including one very valuable tip for those who re-saw on the band saw, but you’ll have to watch the DVD to find out what it is). Every operation is explained to the last detail and it soon becomes apparent why his work is of such high calibre; he pays attention to the smallest detail both in his methods of work and the construction process he has devised for this box. There is much material here and when he covers a complex operation, such as routing the finger joints, he first explains the process so the viewer knows what to expect, then performs the operation for the viewer and then follows it up by explaining the whole sequence again. This is a very easy to follow format.
One thing that quickly becomes apparent as the DVD progresses. Rob likes jigs and uses them to great effect when constructing the box. He provides a thorough outline of the operation of each jig and explains its operational principles in great detail. He provides enough information on the construction of each jig that any woodworker should feel comfortable building one of his or her own. The jig he uses for cutting perfectly round dowels and its somewhat finicky set up is covered as well as the various shooting boards he uses. The jig he uses to drill the hinge pieces was custom made for him by a machinist, and just in case you don’t have a friendly neighbourhood machinist, he provides and alternative shop made version for that as well.
The assembly process is a series of intricate steps that Rob lays out for the viewer with explanations of why he is doing various things at certain times. It is a complex process that Rob lays out with clarity for the viewer, making it seem like a simple walk in the park. The secret here is that it is the methodical
process that makes it much simpler than you would think.
As action films go, it could use some improvement (not a single belt sander race to be found!) but it will certainly keep you watching; it delivers everything it promises in spades. The tips he offers as he builds this box from start to finish in this DVD would be of value to any woodworker but what viewers will really appreciate is the full explanation of the methods he uses. Not only is every detail of the construction explained in exquisite clarity, he often explains the reasons behind the methods he uses. This is valuable information that no woodworker interested in building small boxes should be without. This DVD should be in every woodworkers library - it’s that insightful and well presented.
For the wealth of information packed into this 100-minute DVD, the production qualities that deliver a clear picture and clear sound to the viewer and the precise and well thought out manner in which Rob Cosman presents his material, we would rate this as a must have and give it our highest recommendation.