When I returned to the shop this week, I took the clamps off the box and checked out the assembly. Things looked good, so I moved on. Step number one was to add a lid. Because I wanted to hide the lid’s appearance, I created a lip that was slightly less in thickness than the planned corner inlay. After sizing a piece of mahogany to that of the box, I used a two-step cut at the tablesaw to rabbet the piece. The lid was ready, so I glued it to the box.
As the glue dried on the lid, I found a scrap of tiger maple and milled the corner inlay material to size. Off the saw, I ran the 3/16″ piece through my spindle sander to bring them to perfectly square (5/32″) and to clean up any nasty burnt areas. The next step was to rabbet the box for all the corner work. Because the box was square, I could simply use a straight bit set up in my router table. (If any of the edges were rounded or curved, I would have needed a bearing-guided bit.) Set-up of the bit height and fence is critical; if I rabbeted too deep the inlay I made was once again scrap. To dial in the exact setting, I used a piece of the inlay as a guide as shown above.
When the glue was dry, it was off to the router table to trim the corners. I rabbeted only the four face corners at this time. The plan was to install the corners, then when the top edges were rabbeted, the installed pieces would be cut and the those inlays would terminate into the top edge inlay. Bring on the glue and blue tape. (I find blue tape invaluable when working with inlay.) I added a bit of glue into the rabbet, slipped in a piece of corner inlay then taped the thing in place as the glue dried.
To separate the top from the box, I used my table saw. Before making any cuts, I sliced a couple filler strips that are equal to the blade’s kerf. At the saw after trimming any extra lengths of corner inlay flush with the box top, I made two passes along the front and back of the box cutting through its walls. The filler strips were slipped into those cuts, I then added a clamp to keep the top and base in place as the next set of cuts freed the two sections. You can see the operation at the right, but you might also notice that I positioned my clamp in the wrong orientation. I could easily make the first end cut, but I had to add a clamp then remove the first clamp in order to make the second cut. (If I had just moved the clamp, the sections would not have moved, but the filler strips could have fell out causing more work.)
Once the top was off, I returned to the router set-up to run the rabbets for the four top edges and fit corner inlay to the cuts. These pieces required miters at the corners. I used my bench hook and my Dozuki saw to make the small miters. Once cut and fit, it’s back to the glue and blue tape. As the glue on the box top dried, I milled and installed bands around the base of the box – these piece were the same thickness as the corner inlay. I also fit and installed a band around the top edge of the box – these pieces were half the thickness of the corner inlay and a second band was applied to the bottom edge of the top. (When the box was joined and closed, the total thickness of the middle banding would equal that of the corner inlay thickness.) Each of these pieces were mitered at the corners. Everything was set aside to fully dry.
What’s left are the three fan inlays and to sand and finish the box. Oh yeah. I need hardware and a handle, too. Got to get creative for that.
Build Something Great!