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Step 3Assemble The Box (Part 1)
The box has two layers - an outer layer that the veneer attaches to and an inner layer to keep the lid aligned and hold the hidden compartment.
Sand all box parts with the 220 and 320 sand paper until they are nice and smooth. This is to avoid having to sand so much inside boxes later.
Assemble the boxes by applying glue to the edges and pushing them together. Always dry fit your parts before gluing to double check the fit. Use clamps and masking tape the hold parts together while drying.
Glue up the outer lid, inner lid, and outer lower box (separately.) Allow to dry.
The inner lower box requires a miter cut in the top 3/4 inch or so into both sides of each panel. This allows the inner box that shows to have nice clean mitered corners. On two panels its the top tooth that needs to be mitered, on the other two panels miter down to the small 1/8 horizontal cut. Use the coping/hand saw to do this, or use the utility knife if you need to. Dry fit, and once the corners are nice and sharp glue it together. You can fill in any gaps with the light colored wood filler (sand smooth when dry).
Miter one side of the outer side of the bottom door panel at 45 degrees. This will allow it to swing smoothly and be the indicator of where to push to open this compartment. Sand it nice and smooth. Glue the hinge parts together and glue them to the inside of the bottom door panel at the mitered edge.
Make sure the outer box top fits over the lower inner box smoothly. Sand both parts until the top slides on and off easily and smoothly.
Glue the hidden compartment sides into the bottom of the outer lower box (making sure the prop them up the 1/8 inch to allow for the bottom door to close.)
Double check that the magnets fit into the strip, adjust if necessary (a rotary tool is handy for this.) Remove the magnets. Glue the strip that holds the magnets to the inner side of the bottom door, set back 1/8 of an inch from the edge.
Glue the magnets into the strip with epoxy. Use epoxy because it's easy for a strong magnet to hold to metal more tightly than the glue holds to the magnet, effectively ripping the magnet out of it's glue base. Epoxy improves the odds that this won't happen.
Sand all box parts with the 220 and 320 sand paper until they are nice and smooth. This is to avoid having to sand so much inside boxes later.
Assemble the boxes by applying glue to the edges and pushing them together. Always dry fit your parts before gluing to double check the fit. Use clamps and masking tape the hold parts together while drying.
Glue up the outer lid, inner lid, and outer lower box (separately.) Allow to dry.
The inner lower box requires a miter cut in the top 3/4 inch or so into both sides of each panel. This allows the inner box that shows to have nice clean mitered corners. On two panels its the top tooth that needs to be mitered, on the other two panels miter down to the small 1/8 horizontal cut. Use the coping/hand saw to do this, or use the utility knife if you need to. Dry fit, and once the corners are nice and sharp glue it together. You can fill in any gaps with the light colored wood filler (sand smooth when dry).
Miter one side of the outer side of the bottom door panel at 45 degrees. This will allow it to swing smoothly and be the indicator of where to push to open this compartment. Sand it nice and smooth. Glue the hinge parts together and glue them to the inside of the bottom door panel at the mitered edge.
Make sure the outer box top fits over the lower inner box smoothly. Sand both parts until the top slides on and off easily and smoothly.
Glue the hidden compartment sides into the bottom of the outer lower box (making sure the prop them up the 1/8 inch to allow for the bottom door to close.)
Double check that the magnets fit into the strip, adjust if necessary (a rotary tool is handy for this.) Remove the magnets. Glue the strip that holds the magnets to the inner side of the bottom door, set back 1/8 of an inch from the edge.
Glue the magnets into the strip with epoxy. Use epoxy because it's easy for a strong magnet to hold to metal more tightly than the glue holds to the magnet, effectively ripping the magnet out of it's glue base. Epoxy improves the odds that this won't happen.
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Oct 29, 2009. 11:16 AMMrSpinn
says:
How did you carve those notches (dovetails?) They look extremely precise for being carved into 1/8 inch wood.
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2
Sep 15, 2010. 7:05 AMgeoslim13
says:
You can make it precise like that by hand by using a jig that you can buy. my dad has one. Also those aren't dovetails, dovetails look more like triangles. or /_\ .
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38
Aug 15, 2010. 9:17 PM
technoplastique (author)
says:
technoplastique (author)
says:
They're laser cut. I've cut some delicate notches by hand before but it's not easy!
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