Concealed Hinges: Elegance & Functionality Combined!

Polmac (UK) Ltd supplies a large number of customized, wood presentation boxes with hinged lids that are beautifully made, versatile and terrific value.

We use many types of hinges ... large, small, plain and decorative, made from different materials and finishes.

Polmac Ironmongery Showing Round, Concealed Metal Hinges

However, the most popular hinges are made from pressed, sheet steel with a brass, or nickel plated finish, as they are elegant, durable and economical.

Hinges with a special black, or bronze finish, as well as solid, polished brass hinges are also used where specified, although they are more expensive.

Brass and nickel plating on metal hinges is used primarily as a decorative finish but does also provide excellent wear and corrosion resistance.

Hinges must always perform one important function: To secure the lid to the base of the box and allow it to be opened and closed smoothly along a hinged axis, in perfect alignment

No matter what type of hinges are used, they must also enhance the visual appearance of the finished wood boxes. We therefore use special 'concealed' metal hinges as standard, unless otherwise specified.

These hinges are supplied round, hexagonal, or rectilinear in shape and are fixed at the back of the wooden boxes, where only the narrow knuckles are visible, on the outside and the inside, providing a visually appealing, 'clean' look. 

The two flanges of the concealed hinges can be a smooth finish, or have raised 'prongs' in the surface, to increase resistance to extraction.

The fixing process is as follows ...

Firstly, two thin slots are cut into the ends of the base and side panels at their intersection, ready for the hinges to be inserted.

Secondly, the ends of the side panels are cut full length at 45 degrees to each other, creating an overall 90 degree joint. This is a special 'stop feature' which restrains the lid at the vertical position when opened and prevents damage to the hinges.

The hinges are then inserted into the slots and the fixing positions pre-drilled. Special serrated, 'disappearing' pins are then inserted and carefully hammered home.

For small, wooden boxes 6 - 8 mm serrated pins are very effective and these are hammered at a slight angle, to provide a secure and permanent fixing.

The pin holes are then filled with wooden plugs and sanded off, for a smooth, even finish.

http://www.polmacuk.com

Corrugated Metal Strip Inlay Decorations!

Many Polmac, custom made, wooden boxes are decorated using traditional methods, to create visually stunning, decorative designs and effects.

Corrugated, metal strip inlay is a special technique for decorated wooden boxes, that uses flexible, thin gauge, corrugated, or plain brass or nickel plated metal strips, as lines to create patterns, shapes, decorative motifs and borders. 

 

This type of decoration is often used in combination with other techniques, such as pyrography and hand carving, to create original, decorative effects!. 

 

Cutting Grooves Around the Pattern / Design 

The technique comprises three stages…

1/ Creating a design, or pattern on the wooden box.
2/ Using a special tool to cut thin slots around the design.
3/ Applying the corrugated strips.

Once the design or pattern is agreed, it is carefully transferred onto the lid and / or the sides of the wood boxes. This is often done by hand using pre-printed patterns on special see-through paper, similar to tracing paper.

 

Inserting Corrugated Metal Strips Into Pre-Formed Grooves

A pin is then used to apply tiny pin pricks through the paper, to ‘trace’ out the design. However, if the design is simple, or a particular one-off, artistic effect is required, the design can also be drawn using the sharp point of a pencil  

Thin grooves are then carefully cut into the wood around the design, to the depth of the corrugated metal strip using a special, hand held tool, which looks like a cross between a hand carving tool and a chisel.

 

These tools have a range of special cutting edges that can create different shaped lines, such as  curves, circles, straight lines etc.

 

Removing Excess Metal Strip

The metal strips are then tapped into the grooves, flush with the surface of the wood. This process requires the crafts person to wear a metal 'sewing' thimble at the end of their finger, to prevent being cut by the thin gauge, corrugated metal strips.

 

Any excess strip is cut off and the raised edges ‘sanded’ off, on a special sanding machine, to provide a flush, even finish on the wood surface.

 

Polmac Wooden Boxes With Metal Strip Inlay Design

Once the metal inlay process is complete the design can be decorated with multi-coloured, or natural wood stains and/ or block colours, to provide that all important finishing touch!  

http://www.polmacuk.com

Fly Fishing: A Game Of Deception!

Artificial 'flies' are used by anglers when fly fishing, to catch fish. Flies are also described as 'tackle' which means 'apparatus for fishing' and this term has been around since 1398 AD.

Fly fishermen use hand tied flies which they keep in special fly boxes for protection, as they are fragile and can be expensive to replace. 

The flies resemble actual flies or 'lures' and are designed to entice the fish to bite on the fly. This is why there are multi-coloured flies, of various shapes, sizes and designs.

Fly Fishing

Once the fly or 'lure' is attached to the special weighted line, it is cast into the water using a fly rod and reel. This requires special skills and techniques that are different from other forms of casting.

Fly fishing can take place in fresh or salt water. You do however, need to decide what type of fly fishing you wish to do and then learn about the flies that can help you catch your fish.

If you just play it by ear, you could be fishing for a very long time before you catch anything.

In Britain, where there is less variation in water temperature, fly fishing is differentiated as 'game fishing' for trout and salmon and 'coarse fishing' for other species.

Fly fishing in different habitats means that the fly hooks used will vary, depending on the kind of fish you wish to catch.

Freshwater fly fishing doesn't have to be complicated though, so if you're a beginner there's no need to buy an over sized fly box and stuff it full of flies.

Polmac (UK) Ltd Single & 2-Tier Fly Boxes

Polmac (UK) Ltd supplies custom made, wood fly boxes, finished with a special water-proof, clear lacquer finish and supplied with internal, rigid foam inserts to protect even the most delicate of flies.

They're beautifully made, versatile and terrific value and are supplied as single and 2-tier fly boxes, to provide maximum flexibility for every angler!

Polmac fly boxes can also be overprinted with special text or logos, if a more personalized, branded finish is required.

http://www.polmacuk.com 

Wood Glue - Jointing Can Be A Sticky Business!

Using glue is perhaps the most common task in wood box making, apart from cutting and shaping the wood itself.

However, there's often a better understanding of how to cut and shape wood, than there is in the gluing process, which requires great skill and a precise knowledge of the properties of glue.

When viewed under the microscope, wood is a solid mass of fibres, running roughly parallel in one direction and when gluing wood, we can use this fact to our advantage.

Wood joints are always stronger when the wood fibres on two pieces of wood being joined together, run in the same direction.

Applying Wood Glue To Finger Joints

When two pieces of wood are joined together correctly, the wood adhesives that are available today can create a bond that is often stronger than the wood itself.

The fibrous nature of wood allows modern adhesives to provide a very strong bond, right inside the wood itself and not just on the surface.

This fact is important, as it determines how wood bonding techniques are used and applied during the manufacturing of our custom made, wooden boxes.

Generally, the longer the glue sets (ie. remains in a liquid state) the deeper it will penetrate into the wood and the stronger the wood joint will be, potentially.

There are certainly other factors that determine how deep the glue will penetrate the wood. For example, softwoods are more porous than hardwoods and therefore the liquid glue will penetrate a lot deeper than hardwoods.

However, even with hardwoods, there is usually sufficient penetration to form a very strong bond.

In the past, the glue setting time determined the ultimate strength of the joint. A longer setting period meant that the joint was stronger.

However, because of advances in glue manufacturing and improvements in the quality of glues, the relationship between setting time and joint strength is less important today.

Blackpool Rock Has Nothing On Us!

If you’ve even been to the seaside and bought a stick of rock, you may have seen a ring of letters at the end, spelling out the name of the resort...

And have you ever wondered how they get the ring of letters to run the whole length of the rock, so no matter where you break the rock, the lettering is always there and the words are always legible?

Blackpool Lettering Rock

It takes a great deal of skill to form the lettering, as each letter has to be constructed individually and drawn into long lengths. The letters are then put together in a warm, pliable sugar mass, to form the words of the resort and the long rounded shape of the rock.

We're often asked a similar question about the mitred joints we use to construct our custom made, wooden boxes.

Mitred Side Panels Being Assembled

All our mitred joints have a small wooden ‘tongue’ inserted lengthways (just like the lettering in Blackpool rock) and at 90 degrees to the mitre. The question we’re often asked is...'How do you do that?'

The wooden tongue is designed to strengthen the joint and the whole process, like the application of lettering in rock, takes a lot of effort and skill!

Mitred Side Panels Being Carefully Tapped Together

First, the four side panels are mitred at 45 degrees at each end, to form the four corners of the wood boxes. Small, narrow grooves are then machined along the full length of each of the mitred ends. The grooves are cut to the full thickness and half the width of the ‘tongues’

A length of ‘tongue’ is then glued and tapped into one groove at each corner. This is repeated on the three remaining corners and any excess ‘tongue’ removed and sanded off flush.

Wooden Box Carcass In Press

The four mitred panels are then all glued and carefully tapped together, using a small hammer, taking care that the loose ends of the ‘tongues’ are inserted into the corresponding open grooves.

The whole box assembly is then placed in a special steel press for 24 hours. Once the glue has dried the mitred box 'carcass' is removed, perfectly square and ready for the application of the lid and base.

 

A fellow took my photograph, it cost one and three.
I said when it was done, 'Is that supposed to be me?'
'You've properly mucked it up - the only thing I can see
Is my little stick of Blackpool Rock.'

With My Little Stick of Blackpool Rock: George Formby

http://www.polmacuk.com 

Tea Bags: An Elegant & Convenient Way To Drink Tea!

Tea bags are small, porous sealed bags containing tea leaves and are used for brewing tea. Herbs and spices are used for brewing herbal teas, which are sometimes called "tisane".

Tea bags are usually made from filter paper, silk or food|paper and even food compatible plastic. The tea bag is steeped in the water and acts as the tea infuser and this makes it easy and quick to dispose of the tea leaves.

Speciality Teas

Some tea bags have a string attached, with a paper label on top that is used to remove the bag. The label is also a way of advertising the brand and/or variety of the tea being used.

Tea bags are often individually wrapped in small, sealed paper envelopes. This keeps the tea fresh and provides another means of advertising the suppliers brand name. Speciality teas are often packed this way, to differentiate them from other competitive brands!

The term tea bag is sometimes used to describe the paper or foil packaging for loose tea leaves. This is normal in countries where using loose tea leaves is common.

Taylors Of Harrogate Compartmented Tea Box

Tea has been used as a refreshing beverage since about 2000 BC. Indeed, the tea ritual - brewing, serving, and the drinking of tea - persists in many countries around the world, to this day!

It is thought that the tea trade started in China. However, both China and India insist that it was they who discovered the health and dietary properties of tea leaves.

Tea bags are composed of processed tea leaves and filter-paper bags. The buds and tea leaves at the top of the plant are hand-picked. The tea leaves are then prepared by a number of processes including withering, rolling, drying, cutting, and blending, ready for packing.

Taylors Of Harrogate Tea Box With Speciality Teas

Where speciality teas are provided in hotel bedrooms and reception areas, they are often displayed in compartmented and branded tea boxes with hinged lids. This makes it easier for guests to choose the tea they want and the lids keep the dust out!

Polmac (UK) Ltd supplies, custom made, wood presentation boxes, including tea boxes. They are beautifully made, versatile and terrific value, which means they are ideal for displaying speciality teas and are an elegant and effective promotional tool for the supplier and the hotel!

http://www.polmacuk.com

Herbs & Spices: Essential Ingredients We Can't Do Without!

If you look around your kitchen, you'll probably find some herbs and spices stored on a shelf, or in a cupboard. Celebrity chefs are constantly telling us what herbs and spice to use, because they are essential ingredients in modern day cooking!  

Herbs & Spices

The word herb usually describes the green, leafy part of a plant, either fresh or dried. A spice however, is the product of another part of the plant, usually dried, which includes the seeds, berries, bark and fruits.

Many spices have properties that are often described as 'anti-microbial'. This is probably why spices are commonly used in warmer climates, where there are more infectious diseases.

Spices have other uses such as in medicine, religious ritual, cosmetics, perfume, as a meat preservative, or even as a vegetable. For example, garlic roots are often eaten as a vegetable, because of their anti-biotic properties.

Polmac Round, Herb & Spice Boxes, With Lift-Off Lids

Herbs and spices have been used by humans for thousands of years. The ancient Egyptians even used herbs and spices to preserve their mummies.

Herbs and spices grew in the Garden of Eden, according to the Bible and  were therefore highly prized!

The Chinese and Koreans traded spices around 500BC. Shortly after that, the Spice Route was extended from Asia to Europe and eventually to the American Continent.

The Romans introduced herbs and spices into Britain but it was not until the Crusades that Europe entered the spice trade.

In the 1600s, the Dutch East India Company traded herbs and spices and became one of the most powerful trading companies in history.

Many of the original herbs and spices traded in the Middle Ages, like black pepper, cumin, cinnamon, ginger, cloves, and nutmeg and are still used today. Since then, dozens of new herbs and spices have been discovered, each with their own distinct flavour and character.

Polmac (UK) supplies custom made, wooden boxes, in a variety of styles and finishes, including caddy style herb and spice boxes with hinged lids and small, round boxes, with lift-off lids.

Polmac herb and spice boxes are beautifully made, versatile and terrific value, which means they provide excellent storage and will grace any kitchen table, or shelf.

To find out more, please visit our website at...http://www.polmacuk.com