Making Wooden Boxes with Tight Lids

[Matthew Schenker]

Hi Everyone,
OK, I know there is a way to do this, but I can't locate the technique.  I'm looking to create a series of wooden boxes for storing coffee beans, and I need them to have tight lids.

Can someone remind me of the technique involved in cutting the top so it forms a tight lid that can be popped off and on?  I'm pretty sure there's a way to do it so the whole thing is made of wood, without inserts.

Thanks,
Matthew

 

[Tom Ryan]

One technique I've seen for lids (but I never tried it) is this:  Set your router to EXACTLY half the thickness of the wood you're using for the box sides, using (for example) a 1/4" bit.  Before assembling the box, rout a groove at the same distance from the top for all 4 sides, on the inside of the box.  Now assemble the box.  On the outside of the box, rout a groove 1/4" further down the side than the inside groove.  You'll need to tape and brace the cut sides after you do a couple of sides, so the box doesn't collapse as you rout.

Then carefully remove the tape and braces.  The top and bottom may just separate by themselves, or you may need to help a bit with a shop knife along the top edge of the outside groove.  Now the top should fit over the bottom, with a 1/4" lip.  (Note that you loose 1/4" in height in the box by this method.)

Let me know if this isn't clear.

 

[Matthew Schenker]

Tom,
Thanks!  Actually, that might have been the trick I was looking for!

I tried a couple of ways of doing this on the assembled box, and couldn't get it right.

I could do this with the OF1400 on the MFT, which would help make sure the box stays put when I'm routing the outside groove.

Thanks again for pointing me in the right direction.

Matthew

 

[ejantny]

I've used that that way of making boxes in the past. Works great. The box has to be square or the lid will only go on one way. I made a couple for 3x5 recipe cards.
It is a way that Bob Rosendahl teaches on "The Router Workshop", he calls them "Magic Boxes"

 

[Wim]

I have used another methode.
For the body:
Take a strip of wood, width is height of the body and length is circumference of the box with extra for cutting.
Take a strip of 3 or 5 mm of plywood of the same dimensions.
Glue together with the plywood shifted to the top by the thickness of the wood.
For the lid:
Take a strip of wood with the same length and a width of the height of the lid.
Take a strip of plywood withe same length and a width as the lid minus 2 x the thickness of the wood.
Glue together with the plywood in the middle of the strip.
Cut the sides (body and lid) with a 45° miter.
Glue body parts together.
Glue lid parts together.
Glue bottom and top in the rabbets.
Ready.
If this is instruction is not clear, I will make some sketches.

 

[Matthew Schenker]

I've used that that way of making boxes in the past. Works great. The box has to be square or the lid will only go on one way. I made a couple for 3x5 recipe cards.
It is a way that Bob Rosendahl teaches on "The Router Workshop", he calls them "Magic Boxes"

I first saw this method explained at a woodworking show in Canada about five or six years ago.  It might have been  Mr. Rosendahl who was doing the demonstration.  Now that you mentioned it, I seem to remember that "The Router Workshop" was at that show, so it makes sense.

Wim,
I think I see the method you're describing.

Thanks for the techniques!

Matthew

 

[Wim]

My uncle, a furniture maker, showed this technique to me about 30 years ago. At that time I was not very interested in woodworking. Otherwise I would have spent more time in his workshop. He also did restaurations on exquisite antique furniture, amongst others also for the Royal family.

 

[Matthew Schenker]

Wim,
Do you have photos of his work?
Matthew

 

[rustym]

Matt,
The technique that Tom is talking about was done before in either a Woodsmith or Shopnotes issue.  I know it was quite a while back, but when I get home I'll look to see if I can find the issue.

Rusty

 

[Matthew Schenker]

Rusty,
Thanks.  That would be great!
Matthew

 

[Mirko]

Hey Matthew,
I made this box using only mitres, This was a gift,I made for an electrician friend of mine.
The surprising thing is, it was built with a TS 55 saw and a guide rail! all done on the job site.I believe the dimensions are approximately 10"corner to corner and 4" high.
It was built in a couple hours and i used mahogany veneer on 3/4 MDF scraps that I had on site.
1) Once all the parts where mitred I used tape to hold all the parts together while laying them flat.
2) Then flip it over, add glue, and begin folding it up, just like a cardboard box.
3) When you get it taped up, and before the glue has had a chance to dry, I use a screwdriver to burnish all the edges to seal up any hair line gaps.
4) After its dry, clean it up and sand smooth, then cut off the lid.
5) I cut the lid off @ 1" thick that way I have a 1/4" recess to add the underside piece to the lid. If this piece is cut and fit snug inside this recess, it will align and hold the lid tight in place.
6) Finished it up by adding veneer to any exposed MDF edges.

When I did the "crotch mahogany" book match on the top, I cut off 3/4 around the perimeter so i could add the inlay of African Mahogany, once they where glued in place I cut it to final size by mitering it.
note: the grain runs up the side of the box and over the top!

The toughest part was cutting the angles for the corners, I had to use spacers under the guide rail to give me the over 45 degree bevel.

I think its pretty cool that it was made with a plunging circular saw!!
I did not have a table saw with me at the time, but I wish i had an MFT, would have been allot quicker and more precise.

Mirko

 

[Matthew Schenker]

Mirko,
Thank you for explaining the process of making your boxes.  Definitely a great example of what I was looking for!  As you probably know, boxes make great gifts, and I think it would be nice to make ones of various shapes.  Even better, you used the Festool saw to do it, which is the way I'd like to go as well.

I got a lot of great responses here.  But I knew if I asked this question, I would hear some terrific ideas.

Thanks again everyone!!

Matthew

 

[Wim]

Wim,
Do you have photos of his work?
Matthew

As I said, I was at that time not very interested in woodworking. I am an engineer and was working then in the ship's propulsion business.
My uncle has worked for the (in Holland well reknown) Pander company. This company made high quality furniture and before the war aeroplanes. He learnt his skills with working on the record-breaking Pander Postjager, a fast plane to carry mail to and from Indonesia, then a Dutch colony. Then planes were made with wood and fabric. After the war my uncle started his own workshop for all sorts of woodwork. Later he specialized in repairing and restauring furniture. He also made copies of damaged or destroyed furniture and you could not see the difference. My uncle was a very humble man and did not wanted to get wellknown or expanding his one-man operation. So his work for the royal household was to be kept secret. He also did small jobs at site. As he did not had a car, he had made two very ingenious wooden boxes to carry his tools. One fitted in the triangle of his bicycle, the other was placed on the rear-carrier. And so he went to the houses of the rich and famous of The Hague.
It is indeed a pity that nobody thought of making pictures. I have seen some very nice pieces. He died more than 20 years ago, but I still can see him applying French polish for hours until the colour and brillance was right.
Notwithstanding my lack of interest, he has learnt me a few basics about woodworking.
I hope this was not too much off-topic.

Wim

P.S. I just returned from a holiday-trip, so I could not answer earlier.

 

[Dave Rudy]

Mirko,

What a beautiful box!  Great endorsement for the TS 55. 

Wim,

Thank you for sharing that moving story with us.  Makes me feel that my posts are off topic -- this one is right on!!!

Dave