Good morning, I hope everyone is doing well!
Fall has arrived here in Maine—my favorite time of year! The temperatures are cooler, and the colors have peaked. While I didn’t manage to put together my usual fall color batch of boxes, I’ve included a photo from previous years to bring a little bit of autumn to you. Hopefully, by next year, I’ll be back on a more typical schedule now that the new workshop addition is completed and fully operational!
I wanted to share a few updates from the workshop and highlight some exciting things coming up. It’s been a busy but productive year, and I’m looking forward to the projects I’ve got lined up in the months ahead. I’d also love to get your feedback on one of my planned projects—more on that below!
For those who ordered one of the antique newspaper-lined Shaker boxes, thank you so much! I hope you’re enjoying them as much as I enjoyed making them.
Unfortunately, after fulfilling pre-orders, I didn’t have any extras to list on the website. However, I’m currently working on a new round of items that have been requested over the past few months. The bands have been bent, painted, and are well on their way to completion. This next batch should be ready around the first of December—just in time for Christmas! Expect to see divided carriers, round recessed lid boxes, and much more. Keep an eye out if you’re looking for something special this holiday season!
I’d love your input on an upcoming project. After the first of the year, I’m planning to create some pieces using Civil War-era newspapers, which feature articles on battles and historical moments. Tricia and I picked up a large stack of these newspapers a few months back, and I’ve been saving them for something special.
I’m considering incorporating them into trays or carriers where the newspapers will be visible. What do you think? Would you prefer to see them in trays, carriers, or even boxes? Your feedback would be really helpful in shaping this project, so please feel free to share your thoughts!
I’m happy to report that the workshop expansion is fully up and running! The cedar shingles are on, and I’ve added some new equipment that’s making a big difference—a second drum sander, a planer, and a transfer blower to handle the sawdust. This setup allows me to mill more lumber while keeping the main workshop relatively dust-free.
Thanks for your patience while I worked on getting this project finished!
Over the past few months, I’ve heard from fellow box makers and instructors across the country who have had trouble sourcing materials. Several reached out to me, asking if I could sell some of the lumber I mill here. To help keep the box-making tradition alive, I started listing lumber and tacks on my website, and so far, it’s been a success!
Recently, I fulfilled an order for a high school in Massachusetts for 125 students. Who knows—maybe there’s a future box maker in that group? I plan to expand this offering after the first of the year, including various forms, templates, and maybe even a box-making video tutorial. Stay tuned for more!
To make it easier for you to stay up to date on when new items will be available, I’ve added a schedule page to my website. While the dates may vary by a couple of weeks, it should give you a reasonable idea of what’s coming up. I’ll do my best to keep it updated every few weeks. You can check out the schedule by Clicking Here
As always, thank you for your continued support. If you have any questions or would like to share your thoughts on the Civil War newspaper project, I’d love to hear from you!
Sincerely,
Robert LeHay
Hello everyone,
I hope this update finds you well! I wanted to give you a sneak peek into the progress of the antique newspaper-lined Shaker boxes and share some additional updates.
I’m happy to report that everything is on schedule, and I anticipate completing the Shaker boxes around the second week of September. Customers who requested a box will receive invoices shortly thereafter, and any extra boxes should be listed on my website around the third week of September.
Please see below for a few photos and additional updates, including our new Shaker box lumber offerings!
To help keep you updated, I’ve recently added a rough schedule to my website. This schedule provides a general idea of when new items will be listed for sale and when I plan to start and finish future batches. I hope this will be helpful for everyone—especially if you’re looking to purchase an item for a special occasion. You can check out the schedule by Clicking Here.
I’ve received a couple of questions on social media asking if the newspapers used in these Shaker boxes were antique or reproduction prints. To clarify, the newspaper linings are made from genuine antique newspapers, all pre-1900, with dates in this batch ranging from approximately 1840 to 1890. These were carefully sourced from antique shops here in Maine, with an emphasis on finding papers that were not suitable for conservation on their own (for instance, if a large piece was missing). Tricia used acrylic templates to select the best sections, ensuring that each Shaker box has something interesting to look at or read, while also trying to find pieces with minimal damage.
Due to the age of these newspapers, you may notice some variations in the paper, such as minor water stains, color shifts (especially where the paper was folded), minor rips (which have been glued down and won’t get any worse), and minor holes (which are less noticeable due to the off-white paint behind the paper). These characteristics vary from piece to piece—some may have hardly any, while others have more. Personally, I believe these nuances add to the Shaker box's character, making each one truly unique. When you see it, there’s no doubt it’s the real deal! I’ve included a couple of photographs showing examples of these “imperfections.”
In the Photos: Tricia carefully selecting the best pieces to use for our Shaker boxes. An example of discoloration at a seam—this type of variation can be expected in most boxes.
I’ve also received some questions regarding the durability of the newspaper lining, so I wanted to explain the process. Each Shaker box interior is first painted off-white, which helps highlight the text and conceal any minor pinholes or tears. The newspaper is then sprayed with an acrylic sealer to strengthen the fibers and prevent the ink from running. Once dry, the wood is moistened with water, and the back of the paper is completely covered with glue before being carefully squeegeed onto the wood to help remove any wrinkles. The following day, a top coat of clear adhesive is applied to fully encapsulate the paper, followed by another coat of acrylic for added protection and to help the cover slide on and off smoothly. The paper is surprisingly tough after being applied—I can attest to that from trying to sand off mistakes!
Please choose whichever option works best for you.
If you’ve been on my website recently, you may have noticed a new section where I'm offering Shaker box lumber. With other box makers having difficulty sourcing materials recently, many reached out to see if I’d be willing to sell some of mine, knowing that I mill it on-site. This is something I’ve wanted to do for a while, so I figured now was a good time to start. While I don’t plan to make lumber sales a major part of my business, it might be a nice sideline for the future. Choices are limited at the moment, but I plan to add more species, forms, templates, and possibly even a video instructional series for those interested in making a Shaker box themselves. Hopefully, this helps in some small way to keep the Shaker box craft alive! You can view the materials being offered by Clicking Here!
If you have any questions, please don't hesitate to contact me. Thank you once again for your continued support—it’s very much appreciated!
When it comes to crafting Shaker boxes, the choice of lumber and the method used to process it are crucial to both the workability and quality of the final product. Finding the right material for box bands isn’t as simple as heading to your typical lumber yard. Shaker box bands require hardwood that is clear of knots and other defects, and they typically need to be cut to a thickness of around 1/8". While you may be able to find a few companies online where you can purchase thin stock, the person doing the cutting and grading most likely hasn’t bent boxes before, and even minor defects that might seem acceptable can cause significant problems during the bending process.
Before modern machinery, bands for original Shaker boxes were carefully cut and planed using hand tools. Today, with the advent of modern equipment, there are essentially three common methods for preparing wood for Shaker box bands: sawing lumber (from raw logs), resawing lumber, and flitch-slicing veneer. Each method has its own advantages and disadvantages, and understanding these can help you make an informed decision when selecting materials for your Shaker boxes.
Sawn lumber involves cutting the wood directly from logs, air-drying it, and then further processing it by cutting to length and width, followed by abrasive planing (sanding) to achieve the desired thickness. Although the process is time-consuming and results in some material loss due to saw kerf waste and the abrasive planing process, this method, in my opinion, produces the best material for Shaker box bands.
Various sawing methods can be employed—plain sawn, quarter sawn, rift sawn, or live sawn—with quarter sawn and rift sawn being particularly valued for their stability and workability. The primary benefit of sawn lumber over sliced veneer stock is the absence of knife marks, which can weaken the wood and increase the risk of splintering during the bending process. Additionally, sawing allows for greater control over the thickness of the lumber, whereas veneer mills typically offer only specific thicknesses. Air-drying the lumber, rather than kiln drying, preserves the flexibility of the wood fibers, making it easier to bend without cracking. Multiple passes through a drum or belt sander result in a smoother, more stable end product, perfect for Shaker box construction.
Resawn lumber involves taking a thicker piece of pre-sawn lumber and cutting it into thinner pieces, typically using a bandsaw or tablesaw in the workshop. While this method can be effective, it’s extremely time-consuming and is often best suited for smaller quantities of Shaker boxes. It’s crucial to select lumber that has not been kiln dried, as kiln-dried wood can be more brittle than air-dried wood, making it more prone to cracking during the bending process.
Resawing can also lead to significant material waste due to the saw kerf and subsequent sanding required to achieve the final thickness. Although resawing can be successful, it demands precision and care. The process can be somewhat dangerous if not handled carefully, particularly when using a tablesaw, as the lumber being resawn is typically fairly large and cumbersome, often requiring the piece to be flipped due to the limited saw depth.
Flitch slicing is a wood processing technique where a log, or "flitch," is sliced into thin sheets or veneers using specialized industrial machinery. This method is typically used for producing decorative veneers that are glued onto plywood products for use in the furniture and cabinetry industry—although thicker slices can be produced that are suitable for band stock. Flitch slicing is efficient and maximizes material yield, making it a cost-effective option, especially when working with rare or expensive wood species.
One drawback of flitch slicing is the formation of knife marks, which can weaken the veneer and increase the risk of splits during the bending process. Additionally, sliced veneer typically undergoes forced drying to quickly reduce moisture content. While this accelerates production, it can also make the veneer more brittle compared to air-dried sawn lumber, which retains more of its natural flexibility. Despite these drawbacks, flitch-sliced veneer is often chosen for its efficiency and cost-effectiveness, particularly in larger production settings.
At LeHay’s Shaker Boxes, we choose to saw our lumber directly from logs, as described in the first method shown above. I believe this approach offers the best balance between quality and efficiency.
We start by sourcing high-quality logs from local lumbermen in Central Maine, supporting our local economy and ensuring the best material for our Shaker boxes. Once the logs arrive at our workshop, they are sawn into lumber using a Wood-Mizer bandsaw mill, allowing us to precisely control the cut and thickness of the material. After sawing, the lumber is air-dried—a slower but gentler process that maintains the natural flexibility of the wood fibers, crucial for bending stock. Once the lumber has been air-dried, it’s cut to length and width, then run through a drum sander to achieve a smooth, even surface. This ensures that the wood is ready for bending and finishing, with the ideal thickness needed for Shaker box construction.
All of the methods discussed can be effective for creating Shaker box bands, and I’ve used each one at various times. However, in my experience, sawing bands directly from raw logs yields the best quality material for bending.
Have you worked with any (or all) of these methods? If so, I’d love to hear your opinions! For more information on Shaker box making and to explore our range of high-quality sawn lumber, visit our website by Clicking Here!
Hello everyone,
I wanted to share a few updates from LeHay’s Shaker Boxes. I’ve been busy in the workshop and have several pieces of news to share with you!
New Items Available on July 10th
I’m happy to announce that a new batch of Shaker boxes, carriers, and trays will be available for immediate shipment on our website on July 10th, 2024, at noon EST. This latest collection includes a variety of items, from stacks to individual Shaker boxes, as well as Shaker-style carriers and trays. As always, each piece is crafted using locally sourced lumber milled on-site. Pictured below are just a few of the items that will be available!
Medium Sewing Carriers with a Papered Interior!
This release includes a dozen medium sewing carriers with a papered interior, featuring the same vintage floral design paper used in the trays from earlier this year. These carriers are both practical and a perfect match for those who already have one of the trays! You can view additional information on this item by Clicking Here
Workshop Update
Our new workshop addition is now up and running, which is great news as it allows me to continue working on boxes in the main workshop while spending a few hours in the new shop processing lumber. I’m currently processing quartersawn pine for the tops and bottoms. Soon, I'll begin working on quartersawn birch and maple for the bands. This preparation should keep us well-supplied through the fall and winter!
Antique Newspaper Lined Shaker Boxes
I want to thank everyone for the positive response to the antique newspaper-lined Shaker boxes featured in my last newsletter. I'm looking forward to starting the first batch soon, which should be ready by September. I recently found a basket full of Civil War era newspapers that I plan to use for lining some of the new boxes, adding a unique touch of history to each piece. Additional information on paper lined boxes can be found by Clicking Here!
Stay Connected
If you have any questions, please feel free to Contact Me. Additionally, you can use the "Request Button" on product information pages to let me know which items you're interested in. This helps me prioritize what to make next based on customer interest.
Thank you for being part of the LeHay’s Shaker Box community!
Sincerely,
Robert LeHay
As many of you know, in the middle of January I posted a couple of pictures on social media of a new project I had wanted to try for a long time – trays with a paper lined interior. The response was overwhelming – thank you so much!
I just finished the pre-orders yesterday (3/9/24) and decided to snap a few pictures of them before they get packed up and shipped to their new homes.
I actually had a great time working on these – and am in hopes of doing something similar with other items in the future (boxes, carriers, etc).
I did make a fair number of extras, which I’ll be listing on my website in the next couple of weeks (along with a few other items). If you haven’t already, please be certain to sign up for my newsletter here on the website – I always send out an email the day before I list items for sale.
Find below a few photographs - and thank you once again for everyone’s continued support, it’s very much appreciated!
What's happening inside the Shop, November extras, Pre-Order info, and the Shop expansion!
Happy Holidays!
Rob and I would like to wish everyone the Happiest of Holidays and a Joyous, Gentle New Year!
Shop News
Rob has been working on a very tedious yet satisfyingly methodical task the past couple of weeks. He is bringing the raw pine and maple lumber into the shop then planing, chopping and drum sanding all of it. While he works on this, he’s working his way through the classics on audiobooks and is currently listening to “David Copperfield” with “The Three Musketeers” up next!
The next round of orders will be ready in February, and of course, any extras will be listed here with an email as well as Facebook and Instagram posts a couple of days before the sale. 😊
Rob, drum sanding bands and enjoying classic literature - i.e. Multitasking!
Vintage News
If you are following @lehaysvintageshop on Instagram, you will have noticed that I am dipping my toe into the Reels (short video clips). This takes some getting used to. For example, I didn’t realize that when I take video, the sound also comes through on the post! I thought whatever music I chose would block the unwanted video sounds. Like I said, I’m new at it….. So, one of the first little Reels that I did featured Rob’s carriers in the shop and while Ella Fitzgerald was singing as only she can, the tape gun made a most undignified noise! I’m so sorry, Ella!
I have several items to list from my most recent jaunts, these will be coming along after the holidays as I have been rather distracted with my other favorite pass time this week: BAKING!! I use old family recipes and sometimes I even use vintage kitchen tools!
Fun Finds!
The Shop Critters
As you can see, each employee has a unique viewpoint on the start of winter:
Buzz will nap in his Buzz Buggy until summer. He sends his regards.
(Since he insists this stay in the living room, we did our best to make it part of the holiday decor)
Jonesy, Head of Security is taking a hard pass on winter and is fully retired as of the December 17th snowstorm.
Zoe is handling the details from her home office.
Porter, General Manager is all about increasing enthusiasm and morale with more WALKS!
Happy Thanksgiving!
This is a favorite holiday for us here at the Shop. There will be lots of cooking, eating (stealthy sharing with critters under the table :-), and the company of our loved ones. We hope all of you enjoy the day in your own special way!
November means that we are heading into another Maine winter and all that comes with it. The woodpile is growing, the lumber for boxes is safely in the shed, “studded snows” are on the vehicles and parkas, sweaters and flannel have replaced shorts and sundresses (sigh).
Storing lumber for the winter. General Manager, Porter being Super Helpful.
Jonesy sporting his favorite cardigan, he is the "Boss Man"!
Shop News
Rob is busy getting orders out. He’s shaping and painting carrier handles as I write this. Any extras will be listed here on the website with a Facebook post a couple of days prior.
Rob attaching a handle to #0 Carrier
Carrier handles ready for paint
Vintage News
I have so much fun with my vintage finds – I love to take photos, do research and set up displays! Some of the items have pride of place on my apple wood shelves for a while before I can part with them. :-) We've had snowy roads for a couple of days, but I'll be going back out shortly to see what I can find to share with you!
Recent finds: Antique Quilt, Baby Shoes, Socks on a wonderful old sled. The mittens I've had and enjoyed for many years.
A few of my favorites!
Shop Critters
Meet Zoe. She’s very vocal, her constructive criticism can be scathing! However, her positive reinforcement in the form of <infrequent> snuggles is most welcome. She is the Queen!
Finally Fall!
Autumn is upon us here in Maine bringing crisp mornings and warm afternoons. Perfect weather for outdoor tasks such as painting the house (finished last week) and expanding our walking trail through the woods to the abandoned railroad tracks that run along the property. The expansion has included a water source with an old-fashioned hand pump and adding a small pond in the clearing. I’m pleased to announce that the small pond is inhabited by a large bullfrog named Hercules. Apparently he is embracing the “Tiny Home” trend….. There are plans for a screen house but that will be on next year’s list!
A Carpet of Autumn Leaves on the Cedar Walk through the Woods
An Old Fashioned Hand Pump, Just Right for Watering Next Year's Flowers!
Walking the Abandoned Railroad Tracks Near The Shop
In The Shop
Rob is currently working on November’s orders, as I write this, he is putting the second coat of milk paint on the boxes and carriers. As always, he will list the extras here, on the website. He will give as much advance notice as possible. He is also working on developing a new type of box that will blend old and new in a useful and aesthetically pleasing way, more to come on that….
Speaking of blending, Rob and I did our first collaborative newsletter recently and it went quite well. This isn’t something we will do often but it just happened that we both had items ready to go at the same time!
Vintage News
The next Vintage Newsletter will be ready to go within a couple of weeks. I have had really good luck and so much fun (a trip to Camden, Maine!) finding nice pieces lately! There will be a couple of extra special pieces this time, we’re really “pushing the boat out”! I always try to have a variety of items and price points available; I am also open to requests – searching and finding is such fun! You can email me at tricia@lehays.com.
The View from the Deck of Marriner's Restaurant in Camden, Maine
So sometimes I get to have a good giggle while poking around the antique shops. Here's one of those giggle moments: I found a small collection of vintage cosmetics, one of the tins was “Pompeian Vanishing Day Cream” from the 1920’s. A selling point listed on the back: “Will Not Grow Hair, Satisfaction Guaranteed!” Well, that’s a nice feature…… Tee Hee!!! :-D
Shop Critters
You’ve met Porter, General Manager and Jonesy, Head of Security. Now, I’ll introduce Buzz. Buzz fills a dual role as Morale Officer and Chief Head Booper. But his willingness to HELP has no limits……
Buzz, HELPing Me at my Desk, Coming in for The Head Boop
Eager to Jump in and HELP at The Shop!
Always Happy to HELP with Packing and Shipping!
News from Maine
We have survived the July Heat Wave! Temps topped 95 degrees for several days in a row and the humidity was most unpleasant….. To say that those days were spent in a dewy haze is an understatement. It’s quite shocking for us when you consider that it can (and does) get as far as 30 degrees BELOW ZERO in the winter and nearly 100 degrees ABOVE ZERO in the summer! A 130 degree difference!
Porter Handling the Heatwave
Trail Magic
Somewhere in the middle of that heat, Rob and buddy, Scott decided to do some “Trail Magic”. Trail Magic happens when kind, generous folks who are often hikers themselves set up near a trail and offer food, drinks and other goodies for the hikers currently on trail. Rob and Scott loaded the truck: grill, groceries, chairs et al and set off for the Bigelows near Flagstaff Lake in Western Maine. The menu featured omelets, corned beef hash, home fries, fresh fruit, juice, soda and of course, beer! Those Appalachian Trail hikers were very appreciative! One of the hikers recognized Rob from the YouTube videos of his AT hike last year and immediately shouted, “Shaker Hikes!” Rob did a little video of the day – you can see the “Gourmet Trail Magic” by Clicking Here
Rob, Scott and A Couple of Hearty AT Hikers
Scott at the Grill: Omelets, Home Fries and Sausage for the Hungry Hikers!
This little adventure has Rob considering another AT hike for next year! Stay tuned…..
Shop News
The kiln is full of beautiful pine boards drying in preparation to be shaped into the tops and bottoms of boxes and carriers. The heat has helped that process along nicely! Luckily the woodpecker family who nested in the kiln has moved out just in time for the pine to move in. Meanwhile, Rob is putting the finishing touches on several small carriers that he is planning to list right here on August 24th around noontime.
Carriers to be Listed 08/24, In Progress and Finished!
Vintage News
I’ve been tooling about the state this summer in search of new, interesting, and fun items for the Vintage Shop. I also carry a list of requests with me – right next to my purse snacks! If you have a particular item in mind that you would like me to add to my list, drop me a line at: tricia@lehays.com. I love the thrill of the hunt!
Shop Critters
You all know Porter, The Shop Dog, official title General Manager. Over the next few months, I’ll introduce the rest of the staff!
Jonesy, Head of Security - Semi Retired
Thank you for your continued support, see you next month!!
