!http://farm3.static.flickr.com/2543/4186890746f85820eef7s.jpg(orangutan head as it will attach to sliding lid)!
The reason I quickly found the need to model the carving in plasticine was that I had to see how the idea I had visualized could relate to the size and shape of the box.
From the model I could take measurements of the size and shape that the blocks of yellow wood needed to be to accommodate the carving.
Just to show the rough sketches used to determine the outside dimensions of the wooden blocks I would need.
I could then construct these blocks and cut them on the bandsaw to fit the lid.
Here we see the small block for the hand which will also be the handle for the lid locking peg.
This will be a 3/8” dowel and this is the time to fit the dowel to the hand and drill through the lid and the box a 1/2” hole that can accommodate the pin of the lock. These holes must be perfectly perpendicular to the top of the lid and line up when the lid is fully closed and with the hole in the hand. This is best done while the hand block is in its uncarved form on a drill press so that it can be clamped flat to the press.
First I drill through the lid and into the box with the lid closed and held in position with blue masking tape. About 1” depth into the box seems to work. Of course this has to be positioned so that the hole in the box is well clear of any of the box cavity(s).This is done with a 1/2” bit and then the lid is taken off and inverted over the hand block to act as a guide to drill into the hand a 3/8” hole about 1/2” deep into which the peg is then glued. Any excess glue is wiped off and the locking peg is then inserted into the closed box so that it is held in perfect alignment while the glue dries.
So with the two blocks formed and fitted to the lid and the locking peg working, the wood was ready for carving.
To be continued.
-- David Australia