Well the top shell glue up was successful but I’m not going to show you yet, you’ll have to wait. Its good. Well I think so. Next we need to make the bottom shell. First we’re going to need some measurements. Width
92mm (you can do the maths, divide by 25.4 or multiple by 100 and divide by four for an approximate figure) and depth
51mm. To make the actual shell a tight fit I subtract 1mm from the width making 91mm (fold up and glue line add a tiny fraction almost making up this millimetre). I also add 5mm to the height as there is going to be a 6mm plinth attached around the base of this bottom shell. So thats +6mm -1mm = 5mm (so that it just doesn’t touch the inside top of the top shell). This allows for calculation of the board size as 2 x height + width (you’ll see when I mark it out) that is (2×55) + 91 = 201mm.
As its a square box you’d expect this to be 201mm square, wouldn’t you. Life is never that easy. Always measure both width dimensions. This one is 201×201.5mm. Usually I make these bottom shells from 3mm Birch aeroply. I feel adventurous this time and there was some sycamore left over, which I re-sawed and glued up thus
Cleaned up and thicknessed to about 3mm on the drum sander it looks like this
It never ceases to amaze me that two knot holes on book-matched wood looks like a pair of eyes. Can’t figure the expression on them this time though. For even grain coverage on the finished shell I mark up the net for it at 45° to the grain direction.
See where the 2 x height + width comes from? This is trimmed down and taped ready for EZ-mitre
The bit in the router here is the same 45° bit I used for the mitres in the top shell. After whizzing through all four sides it looks like this
The four corners are chopped out with a knife
and the result folded up, glued and taped to produce this
In the next part we see how well it fits. Adjust as necessary and add the plinth
Be seeing you.
-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com