So the boxes that I posted the other day have generated quite a few questions in the comments and a few PM’s asking me more detailed questions. The number one thing I have been asked for are the dimensions of the boxes. Well, its not secret how/where I got the idea for the boxes, poker chip boxes. So basically what I did was take my poker chip box that I bought a long time ago…
and take the measurements of the inside..
and make it to be the same..
The inside dimensions of the box are 11 1/4×6 7/8. I used 1/2 material, so the outside of the box is 12 1/4×7 7/8.
The next question is how I did the Lid. I drew a to-scale diagram showing the cut outs for the lid and bottom, the diagram also shows the height of the box.
The process of the box is quite simple. These boxes are made with finger joints, so I cut them first, then I cut the grove for the bottom and the top. Then I fit the bottom, and then I cut and fit the top. Once its all good, I glue it up. I cut the top off when the glue is dry. The actual height of the lid is not actually that important, but I usually try to cut it so the fingers will still have the same orientation as before. I use a thin kerf table saw blade so I remove as little as possible. Then I use a block plane a put a small chamfer on the edges.
Hinges: For most of the boxes that I make, I am sold on sold brass Brusso hinges. They are expensive, but I feel they are well worth the extra cost., also, because I usually get the box hinges with a 95° stop, I don’t have to use a chain or any other kind of stops. They look cleaner and are less complex. On some boxes, I just line the bottom and make the lining an extra 1/8-1/4 higher so the top just slips on..
Doing this does not require any expensive Italian hardware which brings us to:
Materials cost per box is going to be $25-$50 depending on the variables. Then my time… it adds up fast. Rule #1… never apologize for asking what its worth.
Hope that answered most questions,