Box making Curved Front Box #15: Completion and Dry fit up of the Trays

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Blog entry by robscastle posted 11-27-2013 01:10 AM 1412 reads 0 times favorited 2 comments Add to Favorites Watch
« Part 14: Starting the internal trays Part 15 of Box making Curved Front Box series Part 16: Finished in its Raw Form »

I continued from yesterday, cut dovetails for the rear section joints and butts for the front

The bases were plywood shaped and rebated on the bandsaw and shaper

The process was fairly straightforward.

Cut the tray frames to fit the internals of the Box base,then cut the plywood to match the frames

Route a rebate into the tray frames

Now this step again had me thinking again, cutting a slot or rebate in straight timber is no challenge, but cutting a piece of concave timber was.

I did not have a slotter bit with a bearing capable of cutting the inside of the curved front to the depth I required.

Simple I thought I will phone up and get a bigger bearing, but that was not to be so as the ID was bigger when wanting 38, 40, or 45mm OD

I wandered about checking every router bit In had, telling myself I could not believe i did not have one that would do the job, the perils of working in miniature!

Then as I was looking at my set of “junk budget” cutters. I saw something that could work.

I used the 1/4 Round over bit as shown its a modified bit with a bigger bearing, most people just remove the bearing but not me I stick a bigger bearing on!

The wing was exactly the size I wanted so I removed the original bearing and replace it with a larger one to obtain the depth I needed.

So there you go, need a shallow groove with a slight round on one edge in very thin timber?

I then used a cove bit for a finger grip on the center piece

Once I had then all assembled some fine tuning was required

Then the final dry assembly

The bases

The tops

All looked OK so I thought I had better drop them in for a check up.

The bottom tray

and The top Tray

Now its off for glue up and hopefully nothing moves out of square.

A question do you think they need a sub divider?

Coffee time!

-- Regards Rob

2 comments so far

View stefang's profile


17040 posts in 4418 days

#1 posted 11-27-2013 08:21 AM

I’m for more dividers, otherwise the jewelry gets all mixed up. I would suggest some rectangular large areas for larger necklaces and a bunch of small ones for rings, earrings, etc.

-- Mike, an American living in Norway.

View BobWemm's profile


2971 posts in 3010 days

#2 posted 11-27-2013 11:15 AM

That’s coming along very nicely.

-- Bob, Western Australia, The Sun came up this morning, what a great start to the day. Now it's up to me to make it even better. I've cut this piece of wood 4 times and it's still too damn short.

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