A Novel Way to Set a Box Lid

Intro: A Novel Way to Set a Box Lid

So you are making a box and you are looking for a way to fit and register a lid to your box. There are several traditional approaches, among them a rabbet in the lid, a slide-in lid, a hinged lid, or liners fitted inside the box. I will show you a novel way to make a lid register in position and stay on your box.

I have not seen this done before. If you have, please let me know in the comments.

For another approach to setting a box lid check out my Instructable here:

https://www.instructables.com/Suspended-Box-Lid/

Short video:

STEP 1: Preparations

Make a wooden box to your preferred dimensions and make sure the top is flat. To make a lid prepare a board that is slightly larger than the box. There are many Instructables and videos on how to make a box, so I won't get into that. You can even buy wooden boxes at a hobby store. The board for the lid needs to be slightly larger than the box.

STEP 2: Notch the Box

First you cut four notches at an angle across the top of the box as shown in the pictures. I use a table saw and miter gauge set to 15 degrees. Cut the notches to about 1/4” (6mm) deep by 1/4” (6mm) wide. Adjust the miter gauge to -15 degrees and cut the second set of notches. Because of the angle the two notches will be spaced farther apart on one side, and closer on the opposite side. You may also cut the slots through three sides as shown in the curly oak box in the intro. Angles between 10 and 30 degrees should work well. Other arrangements, like a cross are also possible.

STEP 3: Cut Wooden Strips to Fit the Notches

Cut two narrow strips of wood to fit snugly into the notches. Use a contrasting wood as an accent to your box. The strips should stand proud of the box walls when inserted into the notches. This is important for the next step!

STEP 4: Glue the Strips to the Lid

Insert the wood strips into the notches across the box. Put some wood glue on the top of the wood strips - top only! Then align the lid with the box and lay down onto the strips. A weight or clamps will hold the lid in place while the glue dries. Just be sure you don’t glue the strips to the box! Extra tip: I used a small amount of paste wax to coat the notches. Glue will not stick to it, and it can be removed with mineral spirits later on.

STEP 5: Trimming

After the glue dries remove the lid and trim the depth of the strips so that the lid lays flat on the box when inserted into the notches. I used a chisel and card scraper to slowly adjust the depth.

Put the lid on the box, it should fit snugly. Turn the box/lid upside down and mark the outline of the box on the lid. Finally trim all sides of the lid flush with the box using a saw, hand plane, or bench top sander. 

STEP 6: Finish

You now have a keyed lid that inserts only one way and stays in place because of the angled strips.

Most unusual! People react confused / impressed when they try to figure out the lid.

Glue a handle to the lid if you wish.

STEP 7: Some More Options

Here are some other arrangements.

Comments

[rubix1976]

Combining this idea and your other box 'structable on box lid design, I wonder what it would look like if the notch\strips were both above and below the lid. I'll let you decide if it would be easier to have the lid in three parts and try and align them perfectly, or to "cheat" and have a top and bottom strip that you can glue above and below the lid "hiding" the joins so it looks as if you've made as I mentioned earlier. Cool idea I love it !!

[rschoenm]

Interesting idea. I think it would be difficult to make the lid in 3 pieces, so I would glue a strip top/bottom and line them up accurately. Thx for your comment!

[jrgospod]

Still can't get "Add Image" of the "I Made It" to work. It highlights gray and nothing happens. Then it won't let me post. It says please attach images. Here is two link.
https://drive.google.com/file/d/1ZvT07rte_o1erANkU2R_CWLNNNWUwexa/view?usp=sharing
https://drive.google.com/file/d/1ZvT07rte_o1erANkU2R_CWLNNNWUwexa/view?usp=sharing

[rschoenm]

That is a beautiful box! Thanks for sharing!

[jrgospod]

Thanks for the video. I liked your lid and used it on a prototype for a box I'm making. I want an oriental look so I left the top hang over (not enough) and added tapered legs. This box (picture) is square but the finish product is going to be about 5" x8" and have more of a overhanging top with the same legs. Again, thanks for the lid design idea.
John
P. S. Can't get add image to work so no picture

[rschoenm]

Thanks for your comment. I'd like to see your box, maybe you can post a picture under the "I Made It" section above! Thx again!

[rpjn59]

That seems like a very 'Japanese ' type of solution. Just my impression...

[rschoenm]

Could be, I don't know. I've never seen this approach before. If you have, please let me know. Thanks!

[VickieL3]

Wonderful idea! I must try this out on my next box project. Thanks for the detailed tutorial.

[rschoenm]

Thanks!

[musingvitality]

Genius , I love the nontraditional solution to a common problem! Thanks for posting

[rschoenm]

Thanks!

[charlessenf-gm]

If the contrasting wood strips stand really proud of the box - say as proud as the lid material is thick . . . then you might construct the lid out of three sections of contrasting material and form the interlocking strips so that they only extended below the lid sufficiently to engage the grooves in the box and were otherwise flush with the inside surface of the lid. Only, of course, if you've got the time on your hands.

[rschoenm]

Thanks for the suggestion. Endless opportunities, if I only had time ...
My problem is that I always tend to move on to the next project :-)

[JohnW51]

Very nice! I love this idea. I've seen other similar designs, but they didn't show any details on how to do it. Thanks for showing that. :-)

[rschoenm]

You are welcome!

[bpark1000]

Cut the strips a little UNDER in height, ONCE. Insert shims in slots to make the strips sit proud for gluing. Remove shims, no need to trim again! (They are hard to trim once glued to the box lid).

One disadvantage is that the strips encroach upon the internal volume of the box. Short pieces of strips could be used instead.

[rschoenm]

Thanks for your suggestions!

[OffshootCreations]

This is an amazing approach, so thank you for taking the time to post an article about it. I have been working on a bird feeder with an unusual design and was looking for a good way to attach a removable lid (without resorting to hooks, latches or hinges), and this one fits perfectly (although I think my lid runners will likely be dove-tailed to keep the lid "locked"). Will link to your article with credits as soon as it's done!

[rschoenm]

Thanks! Please let us know how your bird feeder lid works out!