Above you see the handles attached. After deciding the general shape of the handle and the location I drilled holes and inserted dowels, then glued them up
Next I slide the nails back into place and mark where the handle falls on the side of the box.
Once the area that needs to be removed for the handle is marked I use a flush cutting saw (my best cutting saw) a coping saw, and a sharp chisel to remove the material
Then I reinsert the nails and check for a good fit. This is why I use nails, the lid has to be put on and taken off over and over to make a good fit.
At this point I like to finish the insides. I finish both the inside of the box and the edges and bottom of the lid. It makes everything a lot easier, and I have found it is almost impossible to get a good finish on if it is done any later than this.
Then I sand the nails with 80 grit paper, insert them until the point just holds the lid in place. I then apply the CA glue to about 1/2 of the nail that is still exposed and gently tap in place. I make sure the lid is aligned, add a little extra glue to the hole just for good measure and set a side.
I want to point out here that is is very important to get the whole drilled the correct size for what ever you are using for the hinge pin. The pin attaches in the sides and the lid rotates around it. I do it this way because it is visible on the out side of the box. I also caution you to be careful as you remove and attach the lid. Pull the nail straight out. Try not to rock it back and forth to get it out because this makes the hole bigger and can create problems when you try to glue the pin in place.
Well Christmas is getting close and so is the end of this blog. There are only a few more steps and I’ll be back soon to share them with you. Thanks for coming along this journey, see you next time.
-- JoeyG ~~~ http://www.facebook.com/JHGWoodWorks