I started with a 1/2" x 8" x 4' red oak board from Menards; the cost was about $9 USD on sale. I cut it down to 7" for the top and bottom and about 2" for the front and back. I glued it together in 2 stages. The first stage is shown here:
After the above photo, I put the top piece in place to let it dry so that the front and back walls would be held outward enough. Then I glued the top in place:
Next, I cut the box in half to create a clam shell style. Then I routered the back of the lid and glued on pieces for the side, making sure not to adhere the sides to the lid piece. See photos below:
Next, I drilled 2 holes in the sidewalls and lid to accomodate a finishing nail style hinge. I dab of wood filler late in the process (after oil, below) and the hinge holes are not very noticeable. Designing it this way meant not having to buy hinges or have hinges showing.
Then, I sanded everything flush and smooth at 80 grit, rounded the edges with a router, and then sanded everything finely, working from 100 grit to 400 grit. Next was 3 coats of Minwax Antique Oil that I had on hand. Then it was time to add some felt for the lining. I cut 3/4" tall cardstock for the inside (using a paper cutter to keep straight and square). I used my Jinhao x750 with Noodler's Lexington Grey to color the edges of the cardstock pieces so that no white would peek out between the felt and box when assembled. (My first attempt without coloring the edges didn't look as good.) I glued the felt to cardstock using Aleene's Felt & Foam Tacky Glue from Michael's; (use a coupon and save money). Insert 4 felt strips, lightly adhering with Tombow Mono Permanent Adhesive; (again, don't pay that much, get it with a coupon!). The felt is a mottled grey "charcoal" from Hobby Lobby; the project took 3 pieces.
Next, I made use of DIY tutorial information found here on FPN to make my insert tray. I chose to make each side of a mountain 1/2" and spread the mountain out over 1/2". The valleys are 1/4". I made a slightly wider valley on the left edge of the box (.45") to accommodate my Jinhao 159. I used the aforementioned Tombow adhesive to bond the felt mountain/valley cardstock/felt combo piece to the cardstock base with printed guidelines.Insert pen tray, and it's done. Total cost out of pocket was maybe $13 since I already had the Tombow adhesive, sandpaper, and antique oil.
The finished product:
For what it's worth, this is my first real woodworking project since wood shop class in middle school decades ago. It really wasn't too hard as long as I took my time and thought things through. I hope this helps someone else along the way.
Edited by dvalliere, 02 July 2016 - 02:57.