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I'd go with box joints 
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First off, maybe a little lay out work? I found some 1/4" plywood for the bottom of the box....made a couple marks
Router Plane Box Project, lay outs.JPG
That show one corner, with the amount that needs to be in a groove...
Router Plane Project, outlined.JPG
Then a few more lines...there was a problem....needed to allow for the bit holder..
Router Plane Project, tool holders.JPG
Had to move a couple lines..
Router Plane Project, locations.JPG
Cut the plywood to size. Had a plank I thought I could make some use of..
Router Plane Project, one plank.JPG
Before I could cut the four sides to length, I had to deal with....
Router Plane Prject, wavy edge 1.JPG
The other edge wasn't quite as bad...we have ways..
Router Plane Project, wave reducer.JPG
Ran one edge through, re-adjust the fence, run the other edge through...
Router Plane Project, hand sawn.JPG
Then I could lay out and cut the sides for length....
Stay tuned, part 2 is about to start...
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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.
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Got the 4 sides to size...
Router Plane Project, 4 sides.JPG
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..
Router Plane Project, little off the top.JPG
Just a bit off the top? Aim was to remove the darker stripe...
Router Plane Project, 4 blanks ready.JPG
With about a 1/2" above the top of the plane?
Milled some sockets, then a couple tails..
Router Plane Project, first corner.JPG
Then a second corner was done...
Router Plane Project, squared.JPG
Then swept the floor, and called it quitting time...
Router Plane Project, quitting time.JPG
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...
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Roughly 2 hours, today....made a large, crunchy mess in the shop...
Router Plane Project, crunchies.JPG
Ok, to cut those dovetails....I used a router..
Router Plane Project, dovetail cutter.JPG
And a stop line..
Router Plane Project. stop lines.JPG
Set in the vise..
Router Plane Project, stop line in use.JPG
Mainly eyeballed the sockets...
Router Plane Project, 3rd corner.JPG
Then a chisel or two, to clean things up
Router Plane Project, chisel clean up.JPG
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..
Router Plane Project, test fit 3rd corner.JPG
Then do corner #4....and set up the Stanley 45...have a bunch of grooves to do...
Router Plane Project, reset the 45.jpg
Stay tuned...
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Clamp a side to the bench..
Router Plane Project, bottom grooves.JPG
And run both a groove for the bottom panel, and a groove for a raised panel in the lid
Router Plane Project, top groove made.JPG
While doing a dry fit, discovered the plywood was too narrow..so
Router Plane Project, new bottom panel.JPG
Cut a new one, and a test fit..
Router Plane Project, test fit, bottom.JPG
Did a different approach, to raising a panel for the lid...
Router Plane Project, test fit, lid.jpg
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)
Router Plane Project, panel raiser jig.JPG
With my zero clearance insert panel, to keep things from dropping into the saw...then a back bevel to adjust to fit.
Router Plane Project, just enough room.JPG
Checked to see if there is enough room inside...
There is an extra groove...to help make a dust seal,
Router Plane Project, grooves lined up.JPG
After the glue dries, I can come back and plough the last groove..
Stay tuned...was a busy day..
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Dust seal? The box for my Stanley 45 has one...
Router Plane Project, dust seal.JPG
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..
Router Plane Project, grooves lined up.JPG
Needed to plane and sand the panel...
Router Plane Project, raised a panel.JPG
Might be a bit rough to sand it after the clamps come off...
Router Plane Project, glue up.JPG
Let this mess sit a day...then see about splitting off the lid...
Stay tuned
Last edited by steven c newman; 01-26-2020 at 2:16 AM.
Reason: photo size BS
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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
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Lets see...clamps removed....ends cleaned up
Router Plane Project, second end done.JPG
Stanley 45 set up, and run around all the sides
Router Plane Project, outside groove.JPG
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..
Router Plane Project, thin the seal.JPG
Lid had one corner needing re-glued....Cutter holder installed and drilled for one cutter ( for now)
Router Plane Project, it FITS.JPG
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..
Router Plane Project, hinges.JPG
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....
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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?
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More lid fitting....then layout for a couple hinges..
Router Plane Project, first hinge.JPG
Besides a mallet and a chisel....I need the rest of the proper tools..
Router Plane Project, hinge tools.JPG
Slotted brass screws. Candle to wax the threads...worked a while...
Router Plane Project , hinges installed.JPG
Used the third hinge for lay out work....then fill the box up...
Router Plane Project, open the lid.JPG
And then close the lid...
Router Plane Project, close the lid.JPG
Brass corners, nailed with brass nails....I somehow doubt IF this sort of latch..
Router Plane Project, latch, maybe.JPG
Would work, thinking more on the lines of...
Router Plane Project, lid latch, option 2.JPG
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..
Last edited by steven c newman; 01-27-2020 at 4:34 PM.
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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...
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Latch has some tiny screws...
Router Plane Project, latch install.JPG
Calls for a tiny screwdriver..
Router Plane Project, small screwdriver.JPG
And a small pilot hole drill bit ( nail)
Router Plane Project, pilot hole drill.JPG
Then some stain was brushed on/wiped off..PIP?
Router Plane Box, PIP3.JPG
Router Plane Box, PIP 1.JPG
Router Plane Box, PIP 4.JPG
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?
Stay tuned...
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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..
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