Similar to the box itself, I also cut the tray sides extra wide to improve handling and stability on the box joint jig. Standing narrow stock on end is a real pain. I then cut a panel groove for the bottom’s rabbeted edge. A quick and easy glue-up sat overnight and there we are:
When sizing the tray sides, I was shooting for as close a fit as I could get without being too loose or so large that I had to take off a lot of material, all while trying to account for how proud the box joints would be. I didn’t do too badly. The box turned out to be just a touch off square, so I did have to adjust for that on the sanding platen but not so much that it was a problem. I was happy to achieve a piston fit.
The tray sits proud of the box by a ¼-inch to engage the lid when it’s closed. So, I routed a profile around the top of the tray and hand sanded until the lid tilted onto it smoothly. And this is current state of affairs today:
Next up: hinge mortises and a finger lift for the lid.
UPDATE: I made a short video last night to show a couple of friends how the tray fits. (YouTube, 00:11)
-- Brett — Peters Creek, Alaska
2 comments so far
Madmark2
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3444 posts in 2050 days
#1 posted 04-08-2021 10:21 PM
Very nice.
-- The hump with the stump and the pump!
awsum55
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1285 posts in 1970 days
#2 posted 05-12-2021 04:32 PM
Very well done. I like the design and the piston fit of the tray puts it over the top.
-- "The Answer Is Blowin'n In The Wind" John D, OP, KS
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