Finishing the lid
I wanted to get the lid to fit tight, so I cut a piece of ply to fit the box and then centered it under the lid. I used this to scribe my layout lines.
I taped the corners of the box to help minimize tearout. Pushstick was used for actual operation. 
I busted out Wonder Boy for trimming the lid to perfection.
Finished rabbet. (Note Kristin’s toes)
I cut and glued more keys to secure the miters.
I used a file to follow the plane this time. As long as you work away from the corner, it produces smooth results. You can’t feel the keys when you run your finger over the box.
Finish
I sanded all parts to 220. It was a beautiful California day by the way. Low 80’s with a touch of breeze.
Tack cloth and then Watco Danish Oil. I used a brush to stimple the oil onto the knots.
Closeup on knots with finish.
They remind me of the Petrified Forest.
Another coat and some rubbing and I am ready to post.
-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne
6 comments so far
Scott Bryan
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9030 posts in 303 days
posted 102 days ago
This has been a well documented construction post. You definately stretched yourself on this one. Giz, this has been a nice series that you put your heart into.
Thanks for sharing and the box came together well. I am looking forward to seeing it with the finish applied.
-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.
Todd A. Clippinger
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2536 posts in 581 days
posted 101 days ago
I am with Scott, I just love your documentation.
I noticed that you had the Festool hose hooked to the Bosch sander. Looks like a scene from my shop ;)
-- Todd A. Clippinger, Montana, http://amcraftsman.com
Betsy
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1777 posts in 377 days
posted 101 days ago
Giz——looks like it came out nice. You’ve done a great job documenting the progress.
-- Betsy - GO BUCKS!
gizmodyne
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1479 posts in 571 days
posted 101 days ago
Todd. I think about getting a Festool sander which I have heard good things about, but the Bosch has performed well. I also don’t want to buy their paper.
-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne
Chris
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1221 posts in 472 days
posted 101 days ago
Looks excellent! What an awesome tribute….. THanks you for sharing it with us. :)
-- Chris
Todd A. Clippinger
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2536 posts in 581 days
posted 101 days ago
I have had my Bosch 6” for 9 or 10 years and it just keeps going.
I have had the brushes replaced a couple of times and I have worn out the sanding pads, but these items do not cost much.
The Mirka sandpaper works great and seems to last long enough, but does not cost as much per sheet as Festool.
I have no doubt that I would like the Festool, but I certainly won’t give up the Bosch while it is working so good.
-- Todd A. Clippinger, Montana, http://amcraftsman.com