Small box cutting and sanding technique

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Forum topic by DaveA posted 02-06-2010 02:37 AM 1020 views 0 times favorited 3 replies Add to Favorites Watch
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46 posts in 3315 days

02-06-2010 02:37 AM

I would like to make a small box similar to some I have seen in the projects where the top is almost dome shaped. I read (and I can’t give credit because I can’t find it now) about a technique to use an angle grinder with a rubber backed disc on it. I have never seen or heard of such a disk for a 4” grinder. I only have the overlapping layers on a sanding disk. Will this work, or… any ideas?

Also, what is the trick to cutting the top off a box after construction. I am figuring that at some point the box will start to close up on the kerf or something will shift. Is there a method to stabilize the parts throughout the cutting process?

-- Dave - Milwaukee

3 replies so far

View bigike's profile


4055 posts in 3522 days

#1 posted 02-06-2010 02:50 AM

the sanding disk u have should work, and the trick to cutting off a top is cut two oposite sides first then put shims the same thickness of the blade used in both kerfs then cut one other side and install more shims then make the last cut. or u can just use a bandsaw and u don’t need the shims.

-- Ike, Big Daddies Woodshop,

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2066 posts in 3298 days

#2 posted 02-06-2010 01:42 PM

Is it a bandsaw box? If it is square right now I would take a corner. layout the dome shape on that corner. Make sure you leave enough for final shaping and sanding, the dome tops are hard did one a long time ago for a friend. Just take it down a little at a time as your working around the block corners first. Then after you get it close to the shape you want, start working the rest of the sides. Take your time !!! I used a table top sander to do it. The band saw might work if can make a jig to mount it to the table that will allow you to rotate it while youre cutting it. Top to bottom a little at a time tilting as you go. Then finish with the sander..
( that is if the whole box is round).. be sure to make losts of dust and have fun,,

-- Tim, Missouri ....Inside every older person is a younger person wondering what the heck happened

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46 posts in 3315 days

#3 posted 02-06-2010 05:28 PM

Well, I don’t have a band saw so I guess I will sand…and make lots of dust. As soon as I remake my miter key jig
which absolutely refuses to be square to the table for some reason.

-- Dave - Milwaukee

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