I hope everyone’s had a great start to the new year! It’s been a while since my last update, so I wanted to share how things are going with the Civil War Newspaper Lined Tray Project and give you an idea of what’s coming next.
Early last year, Tricia and I came across a basket of Civil War-era newspapers at a small antique shop. Most of these papers date back to April through June 1862, and they include articles on key battles, notable historical figures, and daily life during the war.
While the newspapers weren’t in great shape—many were incomplete or damaged—I was able to carefully salvage sections to repurpose into these trays. This project has been a way to save and showcase pieces of history that might have otherwise been lost, turning them into something both decorative and functional.
Each tray is lined with a genuine section of the Boston Morning Journal, making every piece truly unique. Some trays feature bold headlines, others highlight longer stories, and a few include articles about events or figures I remember learning about in school—like the “Sleeping Sentinel”, President Lincoln’s famous act of compassion.
Here’s how the project is coming along:
The final step is the oil finish, which takes time since each tray gets five coats to bring out the beautiful grain of the ash bands. I’m happy to say I’m still on track to have these trays completed and ready for sale around the beginning of March!
If the Civil War newspaper lining isn’t quite your thing, I’m also working on some other trays in this batch:
Like the Civil War trays, these are all made with ash bands, quartersawn pine bottoms, and finished in the dark antiqued natural finish. I think there will be something for everyone!
I’d love your input on the best way to handle sales for these trays.
When I made the newspaper-lined boxes previously, I randomly selected a box for each customer. That approach worked well since the linings, while unique, had a consistent theme of advertisements. These trays are a bit different—they’re much more specific, featuring articles about key battles, historical figures, and other topics that might appeal to different people.
To make sure everyone gets a tray that’s meaningful to them, I’m considering listing each one individually on my website. This way, you could choose a tray that resonates with you—whether it’s tied to your region, a bold headline, or a favorite historical figure. This would be similar to how I handle the “extra items” I occasionally list, where I announce the date and time for the sale in advance.
This approach would take more time to prepare (photographing and describing over 250 trays isn’t a small task!), but I think it might be worth it to ensure you get exactly what you want. That said, if most of you would prefer I randomly select a tray for you, I’m open to reconsidering. Please let me know your thoughts!
This project has been a pleasure to work on, and I’m excited to bring these trays to life. From preserving the articles to crafting the trays, it’s been a rewarding process.
Thank you again for your continued support—it truly means a lot. If you have thoughts or feedback, feel free to get in touch. I can’t wait to share the final results with you soon!
I’m excited to share a special project I’ll be starting soon: handcrafted trays lined with authentic Civil War-era newspapers, dating back to 1862.
These trays are not just functional; they’re a way to preserve and celebrate the stories of the past. Featuring genuine antique newspapers from the Boston Morning Journal, each piece captures pivotal moments from 1862, including key battles, notable figures, and other significant events.
Earlier this year, Tricia and I stumbled upon a remarkable find at a small antique shop: a large basket of Civil War-era newspapers. These newspapers, dated from April to June 1862, had survived over a century, likely tucked away and forgotten.
While they weren’t in a condition suitable for traditional preservation, they were perfect for this project—a way to repurpose and honor their stories in a tangible, lasting way.
After careful consideration, I decided that trays were the ideal medium for showcasing these newspapers. Unlike covered boxes, trays allow the articles and images to remain fully visible. Each tray highlights a different piece of history, making every one unique.
The bands of the trays are made from quartersawn ash, a wood I don’t typically use beyond carrier handles. I chose it for its distinctive grain pattern, which adds character to each piece. The dark antiqued natural finish provides a nice contrast to the aged newspaper, further enhancing its visual appeal.
Applying the newspaper to the interior of the tray is a somewhat time-consuming, multi-step process that ensures the paper is well protected while still maintaining its antique charm:
This process not only preserves the newspapers but also creates a surprisingly durable surface that can withstand years of use.
Because of the limited amount of newspaper available, these trays are part of a special edition release. I estimate I can make between 200 and 300 trays, which will be available in four sizes:
Each tray will be lined with a unique section of newspaper, making no two alike.
Before production begins in January, I would love your feedback. If you may be interested in purchasing one when they become available in March 2025, you can:
Your input will help me decide how many trays to make, which sizes to prioritize, and whether any adjustments should be made.
These trays are more than functional items—they’re a way to connect with history, preserve stories, and create something truly special. Whether it’s the account of a Civil War battle, a profile of a historical figure, or an everyday glimpse into life in 1862, each tray tells its own tale.
I’m excited to bring these pieces to life and grateful for your feedback to help shape this project. Together, we can preserve a small piece of history in a meaningful and useful way.
Thank you once again for your continued support—it’s greatly appreciated!
Sincerely,
Robert LeHay
I’m pleased to share that my latest batch of handcrafted Shaker boxes, carriers, and trays will be available for purchase tomorrow, Monday, December 2nd, at noon EST. This batch includes over 75 items, offering a variety of sizes and styles for you to choose from.
I usually list new items on Wednesdays, but with tomorrow being Cyber Monday, I decided to make a small change and release this batch a little earlier. Whether you’re looking for handmade Shaker boxes for gifts or something special to add to your own collection, this batch has plenty to explore.
We had our first snow here in Maine recently, so I took a handful of the new items outside for photos. Below, you’ll find a few examples of what will be listed for sale.
A selection of Shaker Oval Boxes, Carriers, and Trays will be available!
Fixed Handle Carriers offered in a range of finishes!
Several Divided Carriers to help keep things organized!
The full collection will go live on the website tomorrow, Monday, December 2nd, at noon EST. Be sure to Click Here to see the full selection.
Thank you for your continued interest in my work, and as always, feel free to reach out if you have any questions!
Sincerely,
Robert LeHay
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!
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!
