Bahnzo's Box Mods - Hardwood Box Mods and More
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How do you make a Bahnzo's Box mod?
Thought I'd document what goes into each hardwood box mod I make. Here's Part 1. This is all for an 18650 mod.
First, cut a board roughly to length for the mod size needed. Then get out the hand plane and square up the board.
Then measure the side and cut to length. Repeat 3x so you have all four sides.
Each side needs to be the same exact length and width. So back to the hand plane to further square and trim each side precisely.
Don't forget to measure every couple slices or so....
And then finally make sure it's square.
And when you are done, you'll have a little pile of lumber that's perfectly matched and sized.
Dude, I must give you props... I can't believe you do this all OLD SCHOOL with hand tools. I'd be lost without my power tools, not to mention My mods would take absolutely FOREVER to make in this fashion LOL
Great job my friend!
ßrąd
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Part 5:
Once again I use the hand plane to trim the ends, and then soften the corners on the edges.
Then the sanding begins. I start with 100 grit.
I use a dye with water to color the wood.
And then I sand with 150 grit. This allows the dye to soak into the more absorbent "flame" grain, and when I sand, it only removes the upper layer of dye. It's not evident, and in fact doesn't look all that great until later. I then wipe each mod with mineral spirits to remove any dust and oils.
I dye again with a slightly darker dye, this time mixed with a thin cut of shellac.
And then I sand again with 220 grain. You can kinda see the darkness of the grain beginning to come out.
I then wipe down the mod again with mineral spirits to remove any dust and oils in the wood, and then give each mod 2 coats of a 1 pound cut of shellac followed by a 2 pound cut of shellac. I then leave it to dry overnight.
Once again I use the hand plane to trim the ends, and then soften the corners on the edges.
Then the sanding begins. I start with 100 grit.
I use a dye with water to color the wood.
And then I sand with 150 grit. This allows the dye to soak into the more absorbent "flame" grain, and when I sand, it only removes the upper layer of dye. It's not evident, and in fact doesn't look all that great until later. I then wipe each mod with mineral spirits to remove any dust and oils.
I dye again with a slightly darker dye, this time mixed with a thin cut of shellac.
And then I sand again with 220 grain. You can kinda see the darkness of the grain beginning to come out.
I then wipe down the mod again with mineral spirits to remove any dust and oils in the wood, and then give each mod 2 coats of a 1 pound cut of shellac followed by a 2 pound cut of shellac. I then leave it to dry overnight.
wow Ken...more steps I see the more impressed I am!
I like the fact you do it the "old" way!
I like the fact you do it the "old" way!
@VV, And that every step he completes is one step closer to these being for sale!
Thanks again Bahnzo for showing us this.
Thanks again Bahnzo for showing us this.
Part 6, 7, 8, 9, 10 (or so)
Really not much to show for a bit now.
After letting the shellac dry overnight, I start adding the coats of the final finish. One coat per day, 5 coats total, with some very light sanding with a very fine paper between coats. The wood doesn't really start to look good until about the third coat, and five coats provides a good protective layer.
And then after all the coats are applied, it needs about 5-7 days to really cure before I start the buffing/polishing.
Really not much to show for a bit now.
After letting the shellac dry overnight, I start adding the coats of the final finish. One coat per day, 5 coats total, with some very light sanding with a very fine paper between coats. The wood doesn't really start to look good until about the third coat, and five coats provides a good protective layer.
And then after all the coats are applied, it needs about 5-7 days to really cure before I start the buffing/polishing.
Just another photo to enjoy. Ken donated this to PIF for our slogan contest a while back...thanks again Ken! 
14500 Bahnzo Eye Candy http://www.flickr.com/people/87267225@N00/
14500 Bahnzo Eye Candy http://www.flickr.com/people/87267225@N00/
Ken is making me one so hopefully its one of these!
@Bianca that mod is very pretty! Thanks for posting!
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Here's a shot after the 3rd coat of finish. You can see the figure in the wood is really starting to come out and give that 3d effect that makes curly maple such a cool wood.
Ken is that 4 new mods being worked on?? Not wanting to rush or anything, but sure wouldn't mind getting my hands on another!! But can wait in line until everyone has a chance to try one! ;-)
Nothing much to report on the construction line.....5th coat will go on today and then they need to sit for a week to fully dry and cure before I can continue.
I did however get one of those tank mods in the mail today. I ordered a Storm Tank and I have to admit these things are pretty good. They work well with my mods, and a big 18650 battery really powers the tank and puts out some serious fog. I've always just been a dripper and never really liked the cartomizers, but that might all change.
I did however get one of those tank mods in the mail today. I ordered a Storm Tank and I have to admit these things are pretty good. They work well with my mods, and a big 18650 battery really powers the tank and puts out some serious fog. I've always just been a dripper and never really liked the cartomizers, but that might all change.
kt, you've got the one made completely of Becote, no? You have any photos of that you can post? Mine has ends made of what was left over from yours.
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