Here is something I tried out this time to get a nice tight fit between the curved lid and the box. It seemed to work out very well.
Then I sanded out all of the saw marks on the box with 80 then 100 grit. Then I turned that rough-sanded box into a sanding block by tightly wrapping a piece of 80 grit around it. Then I layed the lid on top of the box and sanded from side to side (hold you breath) AGAINST THE GRAIN. I continued that until all of the saw marks were out, then repeated it with 100 grit, then finished both the box and lid with 220 WITH the grain.
I took a photo of the fit this produced, but unfortunately it turned out too blurry…that is what I get for not taking multiples! I will try to remember to take another photo when I get around to putting finish on the box this weekend.
After this I cut off the bottom, cut out the center of the box, glued up the center section, sanded everything, glued on the bottom, then attached the lid with rubber cement and cut out the exterior shape on the bandsaw. Sorry I did not take any pictures of this part of the process…I got lazy! All that is left is finish sanding and finishing. One question, is sanding past 220 worth while?
-- James - www.walnutweasel.wordpress.com