Thread: Hexagonal box lids/bases

were you trying to rebate the box frame for the lid to sit into?

The only thing I can suggest is to cut a circle, preferably using a bandsaw circle cutting jig, and with each segment measure the distance and cu by hand using Japanese flush saw, greater accuracy, and can and sand the final fit

I make the lid and bottom panels as follows:
1. Draw a circle of the appropriate diameter using a compass
2. Draw a diameter through the centre of the circle
3. With the compass centred on each intersection of the diameter and circle, draw arcs intersecting the circle.
4. Draw lines between adjacent points on the circumference - the ends of the diameter and the arcs. This is the most accurate method of constructing a hexagon, as it avoids the accumulation of errors you get if you just step off the radius around the circumference.
5. Cut the hexagon slightly oversize using a hand saw or bandsaw.
6. plane down to the construction lines.

Hex box - Camphor laurel, Jarrah & Tas myrtle small .jpg

Lovely box, that, Alex. Care to give us any pointers?



Brian

Thanks Homey, glad you like it.
I guess the main things are the normal pointers - measure accurately, cut the angles accurately etc. As always, when glued up, ensure the diagonals are all equal.

With this type of lift-iff lid, I cut the slots for the lid and bottom panels, and a slot where you'll separate the lid, on the table saw before cutting the sides to length. The side material should be long enough that you have some spare to use when setting the saw to cut another slot on the other side to finally separate the lid, after the box is glued up. The inside & outside slots are set so their corners line up and the he lid is a neat fit.

Hope this is clear, let's know if you have any questions.

Thanks for that, Alex. My apologies - a vaguely-worded question by me. I should have asked how the top was created. The pattern looks to be part of the lid rather than an insert. A scroll-sawn lid over an insert panel, perhaps?

I was prompted to re-read your detailed contributions to Box Bits on this forum and would highly recommend them to any new box makers. Some great tips and techniques there.

Regards,

Brian

Yes, it's a scroll-sawn insert glued to the lid panel. The most difficult part was shaping the insert after sawing, without breaking it. Also, I had to put wax resist on the panel and the insert, so that any glue squeeze-out could be removed. Very time-consuming work with a cotton bud.

Thanks for your comments about my Box Bits pieces - glad they're helpful.