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Forum topic by Chris Cook posted 04-09-2017 04:11 PM 774 views 0 times favorited 7 replies Add to Favorites Watch
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Chris Cook

328 posts in 2702 days

04-09-2017 04:11 PM

Topic tags/keywords: question

So, I have been building these boxes for Christmas presents. This is the second of my Clemson Tiger Paw boxes. The method I use is to build mitered corners all around into a complete box and then saw off the lid using my table saw. Very standard affair.

I have made a TON of boxes but I have achieved a first for myself!

This box has ZERO square edges

I built two boxes before this one without this problem, I am still baffled as to how I got here, but I am here nonetheless.

I need to saw off the lid.

I have looked at:

1) fencing it on the table saw and I see that all the cuts will slightly mismatch
2) Using my table saw sled and I am convinced all the cuts will be slightly off
3) using my band saw, which I predict will be the end of this box

I am all in a bunch of time so far and do not want to jack this up.

Your expertise is much appreciated!

-- Chris, "all we are is sawdust in the dust collector""

7 replies so far

View papadan's profile


3584 posts in 3790 days

#1 posted 04-09-2017 05:04 PM

Can you run the sides of the box over a jointer to square them up?

View 000's profile


2859 posts in 1321 days

#2 posted 04-09-2017 05:10 PM

1) fencing it on the table saw and I see that all the cuts will slightly mismatch

I don’t see why they would be mismatched? Make sure your saw it dialed in correctly.
They should come out close enough to be able to block sand them on a large flat piece of sandpaper.

View Jerry's profile


3214 posts in 2070 days

#3 posted 04-09-2017 06:17 PM

1) Go back to basics, check all of your power tools for proper setup, IE perfect alignment and square. If your box is not square, it means your saw blade was not set at exactly 45 degrees. Parting the lid from the top almost always results in a tiny bit of unevenness because few of us are perfect enough to push the box through exactly the same way 4 times in a row.

2) get a 2×2 piece of mdf and glue 4 harbor freight belt sander belts to it, place it on the flattest spot in your house, clamp it down, and use it to flatten the two edges where your lid mates with the bottom of the box. Sand the mating surfaces gently, let the sandpaper do the work, rotate the box as you sand o as to not sand unevenly. Use a reference straightedge to check your work.

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be.

View wooded's profile


367 posts in 2693 days

#4 posted 04-09-2017 10:31 PM

Hey Chris…..I think that if the top and bottom surfaces are parallel, the cut corner should match unless I’m missing something here. Drum sander would take care of any issues also.

Also, how did your dust filter problem work out? You were going to let me know.. Joe

-- Joe in Pueblo West, Colo.

View jerryminer's profile


958 posts in 1863 days

#5 posted 04-09-2017 11:20 PM

Tall fence on the table saw. Fence square to blade. Will make the cuts parallel to box top surface.
Sand as need per above

-- Jerry, making sawdust professionally since 1976

View Roger's profile


21006 posts in 3225 days

#6 posted 04-10-2017 04:38 PM

This is an ultimate test it seems. Sorry, but the only .02 I can pitch in is, with all these different suggestions, you’ll have to figure out which one might work the best. Wish you luck. I would definitely make it a point to check and re-check your table saw and any other of your machines. One of them has probably came out of square, which happens. It may be as simple as maybe your table saw has built up sawdust in and around the mechanics of your inner workings, and needs a good cleaning. ????

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

View Chris Cook's profile

Chris Cook

328 posts in 2702 days

#7 posted 04-10-2017 11:03 PM

I appreciate everyone’s feedback and input. I found the cause of the problem being a new 45 degree cut sled I made has a tiny little glue line causing problems. Funny thing is that many things were looking square up until I finished gluing the lid. I checked my squares for square and they are square. I don’t know, I must have gotten slack about something to let that slide through.

Anyhow, I went with the “find the best square top/bottom and run it through” with the plan to fix it through the drum sander. My worst fears were not realized.

Again, thanks for your help.

(Joe, it WAS and IS a flaky capacitor. I moved it around looking at it and it appears to be working for now. It’s a matter of time before I just need to replace it, but at least I know the problem.)

-- Chris, "all we are is sawdust in the dust collector""

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