Needing some advice - Router Forums
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post #1 of 14 (permalink) Old 05-30-2019, 01:48 PM Thread Starter
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Default Needing some advice

Iíve got little problem thatís really bugging me. Iím sure the solution is staring me in the face but, I canít see it.
Iím building a series of boxes of 1/2Ē material. The dimensions are 5Ē high by 12Ē wide and 14Ē long.I want to router the inside edges of the top and bottom to receive 1/2Ē thick stock for the lid and bottom. Iím using a bit and bearing combo to get the rabbet size of 1 /4Ē in a Bosch Colt in their plunge base. My foreseen delimma is that Iím afraid that the router will tip during the cut. Iím maxed out on the depth with the Colt so, an auxiliary base plate to span the box isnít possible. Short of switching to a bigger router with more range of depth, does anyone see a repeatable solution?

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Snowflake, AZ

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post #2 of 14 (permalink) Old 05-30-2019, 03:48 PM
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Interesting. The following is the first thing that popped into my mind, and it's sticking, so looks like all I will be able to come up with.

Make a box, with a bottom, the same height as your box, but a bit narrower, and shorter, then shim it to fit your box. That will give room for your bit, and by putting the pressure on your router on the inner box top, the router shouldn't tip. In fact might not need to shim it, just move it a bit when you get to the side you are routing. When you get thru you've got another box you can use for something or other.

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post #3 of 14 (permalink) Old 05-30-2019, 03:56 PM
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Maybe this video will give you some ideas.


https://bit.ly/2Xb7faN

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post #4 of 14 (permalink) Old 05-30-2019, 05:08 PM
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You could just clamp something to the out side of the box to give more surface. By the way if your top & bottom are made from solid wood, be sure to allow room for movement.
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post #5 of 14 (permalink) Old 05-30-2019, 07:15 PM
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For repeat operations, I would rabbet the inside of the piece first then cut to size to make the four sides. When you assemble the sides, the rabbet will already be there. Dry fit it together with tape and cut the lid off (mark the outside so you know where to cut into the rabbet). Make the rabbet wide enough so that you can band the inside to make a lip for the lid. This will keep the grain as close as possible to the original lines. I would use a bandsaw or scroll saw to cut the lid off to minimize the kerf.

You can fancy it up by using different wood for the lip...

For this first box I would clamp/tape a wider piece on the outside for router support like @Larry42 suggested.
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post #6 of 14 (permalink) Old 05-30-2019, 07:39 PM Thread Starter
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Thanks, guys.
I made a new base plate the same thickness as the stock one. And, wide and, long enough to span the box.
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post #7 of 14 (permalink) Old 05-31-2019, 09:04 AM
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Gene, I make boxes every week with lift off lids. If I understand what you are saying, you want a way to make a lip for the lid. My boxes I miter the corners (see photo) and cut the lid the correct size (same as the size of the box). I then use a router bit in a router mounted in a table to make several passes to cut the bottom side of the lid until it snugs onto the box.
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post #8 of 14 (permalink) Old 05-31-2019, 09:54 AM
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The ideal way of course would be to rout the edges BEFORE assembly but to rout after assembly I would have thought that the router table would be the way.

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post #9 of 14 (permalink) Old 05-31-2019, 10:27 AM
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That sounds to me like a table saw project, rather than a routing project.

Otis Guillebeau from Auburn, Georgia

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post #10 of 14 (permalink) Old 05-31-2019, 01:14 PM Thread Starter
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Thank you for all the suggestions.
These are box jointed containers. The top and bottoms are to be glued into place. The top will be cut off to make the hinged lid. Since the initial order is for 24, I need an efficient method for all of the steps of construction.
Right now, I'm prototyping a single BB plywood container. It seems that constructing the four sides first and routing for the top and bottom will be the most efficient method. And, using a hand held router fits the work flow better. Although, using the table router might be better. We'll see. But, that will be for the next batch....if there is a next batch.
Once again, I really appreciate all the input. You guys are great.

Gene Howe
Snowflake, AZ

'The true soldier fights not because he hates what is in front of him, but because he loves what is behind him.' G. K. Chesterton

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