A couple things I made...

[Magnus]

Ave,
Love the Vexillation...GREAT job. A quick question, if I may: 1.) Does it look like there is even a remote chance that the crest box might split at the front where the wood grain runs parallel to the hair "holes"?

2.) Have you, or any one considered making a steam box to bend the wood to make a crest box. The steam box wouldn't need to be very big, neither would the fire underneath it. We use steam boxes for bending the ribs in boat building and I think this might work for your crests. That way one has the grain going horizontal all the way and no chance of the drill holes breaking the wood. Let me know what everyone thinks.
Salve,
Vitruvius, a.k.a. Larry Mager

Sorry, didn't see your questions Larry!

1), Not really...the wood is just supporting horse hair, it's not under any pressure so as long as your holes turn out ok, the box itself shouldn't be damaged.

2) Your method sounds good...you could also try using a harder wood too in order to increase the box's strenght. I use pine, which is havoc when it comes to drilling the holes cuz the bit will drift, but it's easier to cut with a a hand jig-saw.