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Thread: Best way of cutting lid off box?
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13th February 2016, 06:02 PM #1GOLD MEMBER
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Best way of cutting lid off box?
Hi, I am in the process of making a box 280W x 230D x 150H, to specs. My sister wants a 2nd knitting needle box, bit different from the first shown here
The design of the dovetailed joint box includes overhanging frames for the lid and the base, with a veneered panel of Qld Walnut inside the frame, flush with the frame. The frame is mitred and 12mm thick, and overhangs the box sides by about 12mm on top, and 15mm on the base. i.e the lid frame and the base frames are not identical in size, as a result of a mid-stream design change
I am at the stage of gluing the frames to the top and bottom of the box sides, and fixing them in position with 6mm dowels, but am not proceeding until I get the next stage right in my mind:
I need to cut the box some 30mm down from the lid frame, where I have made a dovetail 4mm wider than the others. I have used both a bandsaw and a tablesaw blade with 2mm thick kerf for cutting lids before, but both methods needed a lot of cleaning up. For some reason the box did not come straight out of the last cut on the tablesaw. Could be the fence is not exactly parallel to the blade when pushed against.
Obviously it will not be possible to rest the box on its side on the base and the lid frames as they are not the same size. So I am wondering if I should cut the box before the lid frame and base frames are attached, but after the matching holes for the dowels are drilled. This will leave a tiny section some 35mm high, 280W and 230D, and the lid frame would be glued to this.
Perhaps an alternative is to fit and glue the top lid to the box, sit the box on 15mm MDF, and run it through the table saw blade, so that the lid is cut away whole. But it sounds a bit risky, especially on the last cut when the lid section drops away near the spinning blade. The box timber is huon pine, and double sided tape doesn't stick well to it.
Anyways, I am open to suggestions on how to cut this lid away from the box, pleaseregards,
Dengy
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13th February 2016 06:02 PM # ADSGoogle Adsense Advertisement
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13th February 2016, 06:15 PM #2
I'd stick with the method you used before. You'll need to run it over the tablesaw before attaching the lid frame, then, once the lid is attached, do the final separation with a handsaw.
Make sure the tablesaw fence is perpendicular to the table and parallel to the blade. I use a magnetic featherboard to hold the box against the fence as I run it through.
Once the lid frame is on, the lid can be removed using a hand saw and cleaned up. I do all my measurements from the bottom of the box, and use it as the datum for all cuts.
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13th February 2016, 06:25 PM #3GOLD MEMBER
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Thanks Alex, I hadn't thought of that method. Sounds good
The only problem I would have with this is trying to glue the lid frame to the box. I would not be able to clamp it down as the upper section is just held by a thin piece of timber after the tablesaw cutregards,
Dengy
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13th February 2016, 09:51 PM #4
Hi DengyCut yourself a thin strip exactly the same width as the saw kerf and fit it into the slot you create when almost cutting the lid off. Then you clamp it down.Regards
And my head I'd be a scratchin'
While my thoughts were busy hatchin'
If I only had a brain.
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14th February 2016, 09:22 AM #5GOLD MEMBER
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Thanks Ruddy, that solution is so blindingly obvious that I am embarrassed to have asked
regards,
Dengy
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1st March 2016, 09:38 AM #6GOLD MEMBER
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Success !
Thanks to the advice given on above posts, I cut right through two sides of the box on the table saw with a 2mm kerf saw blade, and left 1mm on the other two sides. I made some 2mm thick spacers to go in the 2mm kerf, glued some paddle-pop sticks on as stops so the spacers would not slide through to the inside of the box, and fitted the spacers to the four cuts, and taped then in position.
I then glued the lid on to this carcase, positioned by 4 locating dowels, and once dry cut through the remaining 1mm on two sides with a fine tooth saw, separating the lid and the carcase. I then used a block plane to remove the residue of the 1mm on the lid and the carcase. That left minimal sanding of the joint faces of the lid and the carcase.
Job turned out well !!
Thanks for the support guys, very much appreciatedregards,
Dengy
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1st March 2016, 02:52 PM #7
Well played sir ! Looking good
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1st March 2016, 03:06 PM #8
Joe..
go to the top of the class
QEDAnd my head I'd be a scratchin'
While my thoughts were busy hatchin'
If I only had a brain.
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