Hey Michael -
Here's a brief overview of the process:
I made this out of one continuous piece of wenge and did as much to it as possible while it was still one piece. I started with the roundover opposite the edge detail first with a handheld router. Next, I made the dado for the top and bottom on the table saw. Finally I added the top and bottom edge details on the router table.
One thing I try to do whenever possible is to sand and apply one coat of finish to the inside of the box before assembly. That way, you don't have to worry about getting into tight corners once it's glued up.
I assembled it as one piece, put in the splines, sanded them flush and using the handheld router, rounded the corners over. I avoided running over the edge details mostly because you don't have a flat reference surface at that point. If you want to be extra careful, you could start a little ways in from the detail and pull away before you get to the opposite side. Once you have the profile established, it's very easy to match it with a fine rasp, file or just some sandpaper.
After the corners are relatively smooth (not sanded to your final grit), I cut the top off on the bandsaw, and added the handle and hinges, the inside rails and the catches.
I hope this answered your question and please let me know if you would like any more tips.
Jay
Here's a brief overview of the process:
I made this out of one continuous piece of wenge and did as much to it as possible while it was still one piece. I started with the roundover opposite the edge detail first with a handheld router. Next, I made the dado for the top and bottom on the table saw. Finally I added the top and bottom edge details on the router table.
One thing I try to do whenever possible is to sand and apply one coat of finish to the inside of the box before assembly. That way, you don't have to worry about getting into tight corners once it's glued up.
I assembled it as one piece, put in the splines, sanded them flush and using the handheld router, rounded the corners over. I avoided running over the edge details mostly because you don't have a flat reference surface at that point. If you want to be extra careful, you could start a little ways in from the detail and pull away before you get to the opposite side. Once you have the profile established, it's very easy to match it with a fine rasp, file or just some sandpaper.
After the corners are relatively smooth (not sanded to your final grit), I cut the top off on the bandsaw, and added the handle and hinges, the inside rails and the catches.
I hope this answered your question and please let me know if you would like any more tips.
Jay
