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I created this jewelry box as a gift for a friend.  It has a clear top to display pictures through the lid.
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Step 1:

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Sides were cut to desired length.  Rounding the sides required the blade to be at a 45 degree angle with a guide setup with clamps on the table saw, also at 45 degrees.  

Step 2:

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A cardboard template was created to guide the blade height.

Step 3:

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The curved piece after pass through.  It was easier to start with a low blade height and pass each side through and then raise the blade a turn until the final curve was achieved.

Step 4:

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Notches for shims.

Step 5:

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Sides together to insert glue and shim to strengthen the corners.

Step 6:

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Lid edges were cut to same length as base and notched to allow for the plexi-glass.

Step 7:

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Ripped 1/4" grooves to slide in the bottom.

Step 8:

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Used a chamfer bit router bevel the edge where the bottom and top meet.  A rounded bit was used for the top and bottom. 

Step 9:

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Bottom and sims glued and inserted in.  Shims were trimmed with a coping saw.  Plexiglass cut to fit bevel in lid.

Step 10:

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I was originally going to use trim to hold the plexiglass and pictures in place but I opted to cut a 1/4" piece of plywood to hold it in place.

Step 11:

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Wooden feet glued and inserted on bottom.

Step 12:

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Grooves cut for hinges.  It was important to test the depth to ensure the lid opened and stopped at the proper angle.

Step 13:

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Prep for stain.

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Step 15:

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Base to hold the plexiglass was glued with rubber cement and wrapped in velvet.

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Step 17:

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The velvet top on the inside of the lid.  Fit snugly enough it did not require anything to hold it in place.

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Cardboard cut to fit in bottom was also wrapped in velvet.

Step 19:

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Lid wrapped in velvet.

Step 20:

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Finished with and without velvet insert in lid.

Step 21:

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I created 2 trays.  1 full sized to fit the bottom and the other half sized.

Step 22:

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Trays were grooved and glued.  Cardboard was cut to fit the bottoms and wrapped in velvet.

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cgapay (author) 2 months ago

Yes, very carefully with a table saw. I usually lay a piece of stock along the guide to keep the piece I'm cutting flush since the guide is rounded at the bottom and can cause it to not stay square. Run 2 passes, increasing the depth each time.

Brames2 months ago

Really nice instructable! How do you cut the grooves in the small pieces used for the tray? I'm familiar with using a table saw to cut grooves, but it seems like it would be tricky to do with the small pieces.


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