Ute Box Cutting and fixing the ends in the lid

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Blog entry by robscastle posted 09-07-2015 08:05 AM 2455 reads 0 times favorited 4 comments Add to Favorites Watch

Today had me marking out the 45 Deg cutouts for the lid body and the two ends.

Then it was time to cut them out.
I mulled over how I could do this accurately, using a jig saw, power saw or just a plain hand saw.
I decided to use my table saw but in hindsight I should have used a hand saw it would have been a lot easier and produce a more accurate result, and less kerf wastage!

In using my table saw and I tell you, trying to man handle pieces of this size on a small table saw was a challenge to say the least, I guess thats where a radial arm saw earns its keep, nothing moves but the saw blade.

Anyway I set to work, the results as you can see were less than perfect.

Once I got everything cut out I then used four No 20 biscuits in each end to provide alignment and support for the end pieces, even cutting those in was a challenge, then attempting to assemble everything required me having to rubber mallet everything in.

However I did get them all in.

One end was a better fit than the other so lots of glue and sawdust was used to fill the gaps.

Here is the B end in

And the A end in

I put them aside for the day and sanded them in the afternoon

The A end sanded

then the B End sanded

What it looks like on the inside

The A End

The B End

And the overall Result just sitting in place.

The amount of kerf loss is noticable if you take a look at the corners, its no real issue as the lid insert will be trimmed to fit the frame, which is next.

A bit of a raggedy effort but I eventuallymanaged to produce a “just workable ” result.

There is no doubt there are some things you should not try to build in your backyard!!

-- Regards Rob

4 comments so far

View JoeinGa's profile


7741 posts in 2611 days

#1 posted 09-07-2015 10:57 AM

”There is no doubt there are some things you should not try to build in your backyard!!”

Well, this AIN’T_one of them. Because you did a bang-up job on it! Nice!

-- Perform A Random Act Of Kindness Today ... Pay It Forward

View Boxguy's profile


2862 posts in 2872 days

#2 posted 09-07-2015 03:29 PM

Rob, I applaud the effort and the results. It was a daring plan to execute. Angles are tough. Angles and curves are impossible.

-- Big Al in IN

View Joe Lyddon's profile

Joe Lyddon

10859 posts in 4656 days

#3 posted 09-07-2015 05:17 PM

Very NICE… Cool technique…

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:

View stefang's profile


17039 posts in 3938 days

#4 posted 09-17-2015 09:19 PM

Nice fix Rob.

-- Mike, an American living in Norway.

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