At LeHay’s Shaker Boxes, I handcraft each box using locally sourced lumber that I mill on-site. Traditionally, Shaker boxes were made with quarter-sawn pine for the tops and bottoms and maple for the sides. In some communities, birch was occasionally used instead of maple. These materials were not only abundant in Shaker communities but were also durable and ideal for crafting long-lasting, functional pieces. Every box I create uses these same materials to maintain the authenticity of the original Shaker designs. I also offer some of these materials for purchase, so you can create your own Shaker box!
One of the most distinctive features of a Shaker box is the finger (or swallowtail) joint. While this joint is visually appealing, its design serves a functional purpose. Shaker woodworkers understood that wood expands and contracts with humidity levels, and these finger joints allowed the wood to move naturally without causing the ends of the band to buckle or crack.
For a well-constructed Shaker oval box, the proportions of the swallowtail joints are carefully considered. The fingers should gradually taper, ending just slightly wider than the copper tack that holds them in place.
I hand-cut each joint, following the traditional methods used by Shaker craftsmen. Though time-consuming, this process creates crisp, clean lines that machines cannot replicate.
Another key feature of Shaker boxes is the use of copper tacks, chosen for their ability to resist rust and staining. I use copper tacks and pegs made on original 19th-century machines to secure the bands, as well as the tops and bottoms of the boxes. This method preserves the authenticity and longevity of each piece. Each tack is darkened to provide an aged appearance.
At LeHay’s Shaker Boxes, I refer to these pieces as carriers, though many people know them as baskets. Whether you prefer the term Shaker carrier or Shaker basket, both describe a classic Shaker base with a bent wood handle. I offer both fixed and swing-handle designs, with handles shaped in the traditional bonnet style, inspired by the Shaker Sisters’ bonnets. Crafted from ash, a wood favored by the Shakers for its strength and flexibility, these handles are designed to complement the elegant simplicity of each piece.
The Shakers typically finished their boxes with varnish or paint, using a wide range of pigments. Color palettes varied between communities, with Maine Shakers often favoring darker hues. In my workshop, I use traditional milk paint, along with a variety of dyes and oils, to finish my Shaker boxes. As per tradition, the bottoms of painted boxes are left unpainted and are instead dyed and oiled to create a timeworn, aged appearance.
Every box, carrier and tray is branded with the LeHay logo, marking it as a product handcrafted in Embden, Maine.
Covered boxes are branded on the inside bottom, while open carriers and trays are branded on the outside bottom.
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