I'd go with box joints ;)
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I'd go with box joints ;)
First off, maybe a little lay out work? I found some 1/4" plywood for the bottom of the box....made a couple marks
Attachment 424436
That show one corner, with the amount that needs to be in a groove...
Attachment 424437
Then a few more lines...there was a problem....needed to allow for the bit holder..
Attachment 424438
Had to move a couple lines..
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Cut the plywood to size. Had a plank I thought I could make some use of..
Attachment 424441
Before I could cut the four sides to length, I had to deal with....
Attachment 424442
The other edge wasn't quite as bad...we have ways..
Attachment 424443
Ran one edge through, re-adjust the fence, run the other edge through...
Attachment 424444
Then I could lay out and cut the sides for length....
Stay tuned, part 2 is about to start...
Smart, I like the picture that you drew for setup purposes. Spent the day cleaning my shop, still have a ways to go. I should have taken a before and after photo.
Got the 4 sides to size...
Attachment 424453
But.....they were a bit too tall...set the plane on the plywood, and the runners under the plane...and added a second piece of plywood under that....trying to get the height close..
Attachment 424454
Just a bit off the top? Aim was to remove the darker stripe...
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With about a 1/2" above the top of the plane?
Milled some sockets, then a couple tails..
Attachment 424456
Then a second corner was done...
Attachment 424457
Then swept the floor, and called it quitting time...
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I can do the other two corners, tomorrow. Start time was 1445hrs....quitting time was 1630 hrs.
Then, maybe I can run a few grooves? some for the bottom, some for a raised panel top, and some to split the top off.....
Stay tuned...
Roughly 2 hours, today....made a large, crunchy mess in the shop...
Attachment 424493
Ok, to cut those dovetails....I used a router..
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And a stop line..
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Set in the vise..
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Mainly eyeballed the sockets...
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Then a chisel or two, to clean things up
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Then use the "pins" to mark out the tails....bandsaw to cut on the waste side of the lines. And a chisel to clean up....for a test fit..
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Then do corner #4....and set up the Stanley 45...have a bunch of grooves to do...
Attachment 424502
Stay tuned...
Clamp a side to the bench..
Attachment 424503
And run both a groove for the bottom panel, and a groove for a raised panel in the lid
Attachment 424504
While doing a dry fit, discovered the plywood was too narrow..so
Attachment 424505
Cut a new one, and a test fit..
Attachment 424506
Did a different approach, to raising a panel for the lid...
Attachment 424507
Involved tilting the blade on the tablesaw to 15 degrees...( I didn't drive this all the way closed, was hard enough to get it back apart)
Attachment 424508
With my zero clearance insert panel, to keep things from dropping into the saw...then a back bevel to adjust to fit.
Attachment 424509
Checked to see if there is enough room inside...
There is an extra groove...to help make a dust seal,
Attachment 424510
After the glue dries, I can come back and plough the last groove..
Stay tuned...was a busy day..:D
Dust seal? The box for my Stanley 45 has one...
Attachment 424537
Idea is to barely overlap two grooves, one inside, one outside...after the glue sets up, I can use a knife to split the top off the case..
Attachment 424538
Needed to plane and sand the panel...
Attachment 424539
Might be a bit rough to sand it after the clamps come off...
Attachment 424540
Let this mess sit a day...then see about splitting off the lid...
Stay tuned :D
Waiting on Brunch to settle in....might meander down to the shop after a bit, and clear away all of them clamps....8 clamps?
That reminds me...next good pay day, I need to go to Harbor Freight, and buy another handful of these clamps....
Film @ 2300 hrs....stay tuned :D
Lets see...clamps removed....ends cleaned up
Attachment 424589
Stanley 45 set up, and run around all the sides
Attachment 424590
Only to find out the inside grooves wasn't deep enough...tablesaw to finish the split...Stanley 45 reset, seal thinned to fit in the lid..
Attachment 424591
Lid had one corner needing re-glued....Cutter holder installed and drilled for one cutter ( for now)
Attachment 424592
Made sure the plane will fit. Thumbscrew was too long, shorten it as much as I could, and still have a point on the end..
Attachment 424593
Found some hinges. Waiting on the glue to dry in the far corner...need to find a latch....Might have this done by next Friday?
Stay tuned....
Fun part....installing them hinges..and not have the lid "hinge bound" to where the lid won't close all the way.......
There is a wee bit of tear out from the 45 cutting the outside groove....thinking that will be a place to set in the barrel of the hinge?
Debating on doing a small round-over around the top of the lid....right now, it is a hard, SHARP 90 degree edge....maybe a block plane to knock the sharp corner back a bit?
More lid fitting....then layout for a couple hinges..
Attachment 424627
Besides a mallet and a chisel....I need the rest of the proper tools..
Attachment 424628
Slotted brass screws. Candle to wax the threads...worked a while...
Attachment 424629
Used the third hinge for lay out work....then fill the box up...
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And then close the lid...
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Brass corners, nailed with brass nails....I somehow doubt IF this sort of latch..
Attachment 424632
Would work, thinking more on the lines of...
Attachment 424633
Something like this...if bright brass is available.....may go over to Menard's later, and pick one up...
Need to final sand the box, and see about a coat of stain....we'll see....it IS Monday, after all..
Stay tuned..:D
Latch cost $1.99 at Menards, plus tax...finish before, or after I install it....
Might try after a late supper....or, just wait til Tuesday blows in...
Latch has some tiny screws...
Attachment 424664
Calls for a tiny screwdriver..
Attachment 424666
And a small pilot hole drill bit ( nail)
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Then some stain was brushed on/wiped off..PIP?
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Not sure if I'll stain the inside...yet..waiting a day, to let the stain dry...then a top coat.....
Thought about a Stanley label of some sort....maybe print one out?:confused:
Stay tuned...:D
Touch ups for the stain, today.....might as well do the insides....then see about a few coats of Amber Shellac.....
There was a suggestion about adding either felt, or, flocking to the insides....meh.
We'll see how the day goes....stay tuned..:D
Latch is fixed...
Attachment 424709
Inside stained..
Attachment 424710
Just about done..
Attachment 424711
Time to close it up...
Attachment 424712
And sit it on the shelf....
Attachment 424713
Until needed....nice weekend project?