The first casket is done...

So, I made my first coffin / casket. There are some realities which quickly come into play. It's not as easy as you may think, although it's not really difficult. With the chipboard pre cut, and having to measure, decide on spacing, drill and then screw the pieces together, I was done in 35 minutes.

Ok, I didn't have the plastic lining in, I didn't have the handles on, nor did I have the 6 holes in the lid for the "Thumb Screws". However, I am confident that with a jig for the drilling, a solid worktop to ensure the boards don't bow, and with everything on hand, I can do one, on my own in about 40 minutes. Probably 30, even 20 minutes after some practice.

I am considering varnishing the caskets, as it will look a lot better. Witness was surprised at the shape. He expected a conventional coffin shape, so maybe that's to be looked at. Not sure what this market wants. What I will do, next weekend, is strip down this model, and remake a conventional shaped one out of the material. It will give me an indication of the complexity.
I am satisfied that it is a viable option still, and the export market for SKU's (semi knock down units) is still very real! In fact, after much consideration, maybe the SKU export market is rather where I want to play...

Some lessons learned:-
As per my "mentor" Fishman, (http://borntofish.blogspot.com/) I used 5x60mm chipboard screws. I think this is the right choice for fixing the sides to the bottom. However I think for the rest of the construction probably 4x40mm would suffice. Also, getting the pilot hole, and then the screw straight is imperative, else the screws tear through the chipboard and are exposed.

Making sure that screws which would probably be within 50 / 75 mm of each other (at 90 degrees of course), maybe the distance needs to increase as this also caused the chipboard to pop / crack / whatever.

I have made notes on drilling spacing and centers, and will be going to a friends place to look at having some jigs made up. This will save a lot of time with regards marking off and sizing before drilling. Also, it means that a less skilled person could be doing that part of the job.


I will also need to assemble a more sturdy platform on which to work. I used two trestles today, and find that the chipboard will sag, so you need to be more careful when fixing the sides to the bottom that it's all aligned. A better platform will take that issue away. Maybe I should collect the old workbench at Mom's place, and make some modifications to that.

So, although I may not be in the position to make 10 / 20 a day yet, and I haven't even had a go at trying to get some buyers lined up, I feel confident that this matter is on course, and that it can succeed.

Salagatle!