I've just gotten my Incra LS Positioner set up and in use. First thing I did was clean up the sides of some maple. Really slick how with the Wonder Fence you can take off very small amounts. With the Bosch router table & the fence that came with it, the increments are fixed at 1/16", at least with the spacers that came with it.
I started out wanting to make a finger joint box, just to figure out how the LS works. I have a set of Craftsman chisels that came from my former father-in-law. The box they are in and the plastic cradle/insert appear to be made for the set of chisels, but the box is such crap, I have a hard time believing it was original with the chisel set.
At any rate, I decided to try making a replacement box. Turns out the only router bit I have that can be used with the LS is a 1/4" up cut. So, I selected 1/4" Baltic birch plywood for the box. I was very pleasantly surprised how easy it actually is to make the finger joints using the LS. I've never made any box/finger or dovetail joints before.
New box sides with rabbets for the bottom.
I'm ready to glue these together and put the bottom in, but I am intimidated by having to spread glue on all these small fingers and getting the glue distributed to all the corners in a timely manner without created a huge mess. I'd really like to keep the glue off the sides as much as possible. I have considered clipping the head off of a Q-Tip and using the stub end. I don't want to use a Q-Tip straight as I think cotton threads will get captured. What techniques have you guys used for this sort of glue-up?
I'd like to replace the hardware (hinges and front clasp) but I am having trouble finding much of anything. I've checked Rockler, Woodcraft and MicroMark. MicroMark has some, solid bras, but they seem too small. What suppliers have any of you used for hardware like these?
Thanks for any help.