Ute Box Lid framing the top

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Blog entry by robscastle posted 09-10-2015 07:28 AM 1259 reads 0 times favorited 4 comments Add to Favorites Watch

I havent had much time to play with my Ute box the last few days so today I manage to get a bit of “my time” in on it

I made the frame for the lid and the fitted the curved insert, that was about all, a bit of filling to get the dimensions right but enjoyable.

The frame I cut on the table saw and glued up in the morning, I did a prototype to ensure it would fit together correctly first up. All was good so the frame was cut and glued.

The basic shape is a Tee but the lip for the insert is a different dimension to the overlapping edge for the box, this was done for weatherproofing.

I was going to cut everyting on the table saw first up but decided against it and cut the lid insert with a router and rabbet bit later after the glue up tracing the exact outline of the curved section.

The reason for this was to get an exact fit into the frame without any more ugly gaps

As the bit gave rounded corners I decided to sand the corners to match the profile.

This went well and I had to only plane a few spots to get a drop in fit.

Now if you were wondering why there is a trimmer and router in the picture its because tragedy struck

My beloved Ryobi router which I have been giving a flogging for who knows how many years today decided to smoke up mid work and I had to finish off with the trimmer.

Now in the Routers defence Its been on the critical list for some time as I had to flick the router bit and hit the switch at the same time and away it would go! the brushes were OK so I could not determine what was wrong with it and I had a good work around.

Post mortem

Looks like an armature short as the field coils were OK.
So Its dead, and maybe a good thing…!!

Anyway back to the blog I then set everything on the box to check its assembly before glueing it in and profiling the edges.

Its a good result today.

-- Regards Rob

4 comments so far

View Boxguy's profile


2868 posts in 2906 days

#1 posted 09-10-2015 11:00 AM

Rob, you know this looks very coffin-like. I think if the rim you added today were angled a bit it would help it shed water and work the wet away from the joints. this is a beautiful job. I like the concept and you jigs for the glue-up. Looking forward to the final product.

Good luck shopping for a router. Let us know what you choose.

-- Big Al in IN

View JoeinGa's profile


7741 posts in 2646 days

#2 posted 09-10-2015 02:32 PM

Gotta agree with Big Al … are you SURE that’s not a coffin? LOL

The only other thing I wonder about is what the dollar exchange down there? Are small, electric hand tools (like routers and such) priced about the same as here in the US? I’ve seen some folks post from other countries where tool prices are outrageous.

I’m also following along to see the finished product.

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

View robscastle's profile


6735 posts in 2843 days

#3 posted 09-10-2015 08:55 PM

Big Al

Your correct The rim profiling will be next to shed water.
BTW did you check out the BACS I used on the Jig?

JoeinGa and Big Al

Ha ha maybe I should put the router in it!

Price of tools in Aust

There are both discount chains and specialised tool shops around Brisbane
Originally some years ago a Discount store called Bunnings appeared owned by a mining company Westfarmers and as a result the price of tools dropped remarkably, this caused the small hardware stores to close up or sell out.
Then along came Masters, Masters is a spin off of the Lowes in the USA owned by Lowes and Woolworths (A supermarket chain) they say they are losing money but keep opening more stores to compete with Bunnings, go figure (its a bit like saying you have no money for a bigger shed but keep building more!)

Then there are speciality stores similar to Lee Valley called Carba tec and Hare abnd Forbes just to name a few
Carba tec sell Powermatic and festo (bring your wheelbarrow load of money with you) along with their taiwan made and rebadged Carba tec brand.

Hare and Forbes do the same, products are made in Taiwan painted and badged to suit the reseller (Grizzly for instance, which we do not have here but look the same physically but carry different badges and paint scheme.

So back to the price question, Ryobi the router I had is a DIY version and priced at about AUD $90 if its used for industrial purposes or trade work there is no warrany. A matter of value for money application and return of investment considerations when making the purchase, being a DIYer I will look around for a replacement that satisfes the features I am used to. I certainly would not consider a Festo at ths stage.

When the ryobi started playing up I went to buy a replacement straight away but that model was no longer made and as I had a lot of custom jigs for the baseplate I bought one on ebay second hand one but my son had it set up to do router stenciling sign work for a wedding so I did not want to disturb the settings.

-- Regards Rob

View stefang's profile


17039 posts in 3973 days

#4 posted 09-11-2015 08:02 PM

Good going Robert!

-- Mike, an American living in Norway.

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