A box for a router plane #2: Dovetails, grooves, and a raised panel...

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Blog entry by bandit571 posted 01-26-2020 12:30 AM 629 reads 0 times favorited 3 comments Add to Favorites Watch
« Part 1: Lay out, start up Part 2 of A box for a router plane series Part 3: The lid has been removed »

Ok…those dovetails. Done with a router, but, no jig…Starts with two lines

Ones closest to the ends are where the baseline is, and is knifed in. the two in the middle are “Stop lines”..

Set right at the top of the vise. When the router’s base hits the top of the bench, it will stop. A bevel gauge to mark the “pins” and MK1 eyeballs to control the cut in the sockets

Depth of cut is set….goggles go on over my glasses…

Rather messy….this is corner #3, rotate the board and do the same for corner #4…then a chisel or two, to clean things up…

Then, use the pins to mark out the tails. Bandsaw to cut on the waste side of those lines, and a test fit, or two..

Tried the plywood bottom panel…found out it was too narrow ( better than too big?)

So, I made a new panel….then reset the Stanley 45..we have grooves to do..

Mainly for the fence, and depth of cut….clamp a side to the bench..

And plough a groove for the bottom and the top panels…and work my way around..

And a test fit as I went…

After all four sides were grooved, test fit the plane, to see how much room there was..

Should be just enough. Groove at the top is to house a raised panel….

easy enough to do…on the tablesaw…

tilt the blade 15 degrees. Plywood is a zero clearance thing, to keep the panel from dropping into the saw. leaves a nice little wedge, when done. one pass on each edge. Then a handplane, to back bevel the “inside” edges, for a better fit in the grooves….test fit?

I didn’t drive things together all the way, was hard enough knock them back apart, anyway. There are still two more grooves to on the inside..

The other will get done after a glue up is finished. Need to have a bit of overlap, so a sharp knife can be run around, and split the lid off of the box, forming a dust seal.

Hopefully better than this one, on my Stanley 45 box….spread some groove around, and a forest of clamps…

Then sweep up all them crunchies on the floor…

And a pile of sawdust under the tablesaw…and call it a day. Waiting on the glue to dry, for about a day.

Then I can split the lid off, and add the parts to the inside..and see about some hinges, and a latch…
Stay tuned…

-- A Planer? I'M the planer, this is what I use

3 comments so far

View Andre's profile


4832 posts in 3092 days

#1 posted 01-26-2020 05:52 AM

A ROUTER! Where is the fun in that?
I forgot to put a dust lip on my #45 box, may have to improvise and correct that little error?
Building a similar lid for a watch box, had started to hand plane the bevels,,,, but may just switch over to the
Table saw an save some energy:)

-- Lifting one end of the plank.

View bandit571's profile


30062 posts in 3969 days

#2 posted 01-26-2020 07:23 AM

One tip when using the router like this….besides wearing a face sheild or goggles…...don’t open your mouth, unless you like chewing on shavings….was hard enough cleaning them out of me beard…

need a better way to hinge the lid….than what I used for the 45’s box….

-- A Planer? I'M the planer, this is what I use

View sansoo22's profile


1879 posts in 940 days

#3 posted 01-26-2020 09:20 AM

That’s just extra dietary fiber…no need to worry about that. Although I grew up on a pig farm so i learned long ago all tools…even if its just a lowly shovel…is operated with your mouth closed.

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