Wood Fly Boxes

1815 Views 25 Replies 17 Participants Last post by PileatedPhotography, 2 mo ago

PileatedPhotography

Discussion Starter · 3 mo ago

I've been experimenting with some fly box designs. I found precut foam inserts for freshwater boxes, but nothing big enough for large saltwater flies. I tried cutting my own for this one. Made it from some NC walnut. I've got a couple more boxes brewing in the shop with some funky sapele.

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TarponBum

· #21 · 3 mo ago

Awesome fly box! I love the tarpon inlay

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PileatedPhotography

Discussion Starter · #22 · 2 mo ago

It took me longer than I thought to work out the design for this next box, but I finally finished it this weekend. This one is headed to Islamorada!
Big thanks to kjnengr for suggesting seadek. The two tone was exactly what I was looking for. Learning the proper way to cut it was an adventure.

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kjnengr

· #23 · 2 mo ago

PileatedPhotography said:
It took me longer than I thought to work out the design for this next box, but I finally finished it this weekend. This one is headed to Islamorada!
Big thanks to kjnengr for suggesting seadek. The two tone was exactly what I was looking for. Learning the proper way to cut it was an adventure.

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Beautiful work. How did you get the two tone color that way? How exactly did you prep/cut the foam? What did you start out with?

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PileatedPhotography

Discussion Starter · #24 · 2 mo ago

I looked at a couple marine flooring companies. Seadek was the one I found that sold small sheets that I could try out. They have a variety of color combinations to choose from. I think it comes out to around $10 for a pair of inserts. I found some information online about best practices for cutting EVA foam. I went with a double cut carbide bur and bumped my RPMs to get a clean finish. I'm not sure how long the bits will last, but I'll eventually be able to factor those into the overall cost of materials. The 3M backing that comes on their foam makes the installation pretty easy.

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kjnengr

· #25 · 2 mo ago

PileatedPhotography said:
I looked at a couple marine flooring companies. Seadek was the one I found that sold small sheets that I could try out. They have a variety of color combinations to choose from. I think it comes out to around $10 for a pair of inserts. I found some information online about best practices for cutting EVA foam. I went with a double cut carbide bur and bumped my RPMs to get a clean finish. I'm not sure how long the bits will last, but I'll eventually be able to factor those into the overall cost of materials. The 3M backing that comes on their foam makes the installation pretty easy.

So you milled out the area where you see black by hand? Router?

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PileatedPhotography

Discussion Starter · #26 · 2 mo ago

kjnengr said:
So you milled out the area where you see black by hand? Router?

I used a desktop CNC router to mill out the light color layer on top. Getting the right bit and RPM is crucial to getting clean cuts in that stuff.
I made a couple mistakes on my first attempt, but I'll just stick those in my personal box that I built out of pieces that got messed up along the way.

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