Router mill for Curved top boxes

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Project by Warren posted 07-12-2018 10:37 PM 1509 views 6 times favorited 8 comments Add to Favorites Watch

I made a new apparatus for milling concave/convex surfaces for curved top boxes. Here are a couple of examples. The larger boxes here are jewelry box sized, and smaller ones are for garlic/shallots. Material came from large birch and oak tree limbs from backyard.

To mill the tops, I made a fixture that is illustrated in the diagrams and photo below. It can mill convave or convex surfaces equally well. Note that for concave milling, the pivot point is above the work surface, and for convex milling, the pivot point is below the work surface. The router carriage can be positioned up or down to accommdate the required pivot point setup. The concave/convex radius of curvature can be adjusted from about 4” to 12”. Depth of cut and radius of curvature are independently adjustable and I generally mill about .05” or less per pass. A 3/4” bowl type router bit seems to work well, tho a bit of sanding is required after milling to get an acceptably smooth surface. The box joints were cut on a screw driven carriage with DRO on a router table. I used MinWax fast drying poly sprayed on with an ancient DeVilbiss spray gun for the finish.

8 comments so far

View Redoak49's profile


4792 posts in 2788 days

#1 posted 07-13-2018 11:13 AM

Very interesting….well done!

View splintergroup's profile


3848 posts in 2021 days

#2 posted 07-13-2018 04:15 PM

Great solution!

View awsum55's profile


773 posts in 1308 days

#3 posted 07-13-2018 04:53 PM

That jig is genius, I really like the boxes.

-- John D, OP, KS

View helluvawreck's profile


32122 posts in 3666 days

#4 posted 07-13-2018 05:58 PM

This is a very nice jig and beautifully done. These are wonderful curved top boxes. Congratulations!

-- helluvawreck aka Charles,

View therealSteveN's profile


5901 posts in 1373 days

#5 posted 07-15-2018 04:59 AM

Now that is whip smart, nice thinking, really nice application, and some dandy boxes that you just don’t see everyday.

Excellent post, thanks.

-- Think safe, be safe

View NormG's profile


6506 posts in 3803 days

#6 posted 07-15-2018 10:04 PM

Wonderful boxes and great jig idea

-- Norman - I never never make a mistake, I just change the design.

View Gary's profile


1454 posts in 5123 days

#7 posted 07-16-2018 11:20 PM

Smart, sharp and stunning.

-- Gary, Florida

View mcoyfrog's profile


4757 posts in 4393 days

#8 posted 07-30-2018 05:25 PM

WOW thats great, thanks for the details

-- Wood and Glass they kick (well you know) Have a great day - Dug

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