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Old 06-10-2008, 11:02 PM   #1
duckarrowtypes
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Default Designing a template for a clamshell box

I'd like to make a template for a special kind of box that I make. (http://www.shinyphotos.com/images/ready_to_ship.jpg)

A case is two identical halves. Each half is sized thus:
4.5 x 5.5" outside dimension
4.25 x 5.25" inside recess/pocket/cavity that's about 1/4" deep

So the recess/pocket/cavity to hold the photograph would be hogged out with a simple rectangular template but I need to do the outside too.

The rails or frame are 1/8" thick. The entire thing is made out of 1/2" ply.

I'd like to make a template but I'm not sure what the best way is to cut out the outside of the box once I've finished hogging out the inside.

Any ideas?

edit: here's a picture (ignore the hinge for now) showing more detail about the "rails": http://farm2.static.flickr.com/1044/...ca752a9d_o.jpg

Thanks!
Jonathan
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