In my first installment I showed the steps to cut and prep the stock for the custom keepsake box.
This installment shows the steps to glue -up the box and cut the lid.
I begin by gluing in the accent strips on all of the box sides. I am using Holly strips that I sized 1/4” wide by 1/8” thick
I use CA glue and tap them in place.
Once the glue has set up I use a small flex-blade saw to trim the ends flush with the miters.
I use a sanding block to sand the strips flush with the box side.
Now is also the time to sand all of the insides of the box sides up to 220 grit.
In this next photo, I’m using my rotary tool with a 5/64” high speed bit to make small holes in the miters to give the glue joint extra strength being careful not to drill through the side and not drilling 3/4” down from the top of the box where the lid will be separated.
I’ve cut the backer boards to fit in the grooves and do a dry fit to make sure all of the miters fit tight and the box is square.
Now comes the fun part. Laying all of the box sides in the right sequence against a straight edge I tape the ends together using packing tape stretched tight to pull the miters together.
Carefully flipping the box sides over I apply glue to the backer grooves and to the miters.
Setting the top and bottom backers in place I now pull the sides together and tape the last corner together with packing tape.
Squaring the glued box with a framing square I pull the corners tight with packing tape stretched diagonally on the top and bottom of the box.
After the glue has dried and the tape has been removed I sand the sides of the box to 220 grit.
In the next photos, I have set the fence of the bandsaw 3/4” from the blade and have placed the top of the box against the fence. Saw through until the lid is separated.
Lid separated from box
Over to the router to round off the top and bottom edges of the box using a 1/4” roundover bit.
Remove saw marks on the inside edges of the box and lid by sanding with 100grit sandpaper on a flat surface.
Box is ready for finishing and hinges—but not yet.
My next entry will be designing the pattern and starting the intarsia.
-- Mike --www.midlothianwoodworks.com