Lid sides - Router Forums
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post #1 of 14 (permalink) Old 11-27-2015, 04:11 AM Thread Starter
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Default Lid sides

Dont know how to phrase it better than that.
if you have a box with a lift off top, but it locates on an inner edge that stands proud of the base sides, thats the thing I want to know about.
The inner wood can only be 2mm thick at best, and even with my router sled I cant plane that thin.
So, What wood is strong enough for that?
and how do I get it in that thickness?
thanks
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post #2 of 14 (permalink) Old 11-27-2015, 09:01 AM
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Is the 2mm lip on the bottom of the lid or the inside face of the box ?
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post #3 of 14 (permalink) Old 11-27-2015, 09:18 AM
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Could you not make the lip out of the same material as the sides, meaning, make the sides taller and then rabbet to that thickness and height...?
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post #4 of 14 (permalink) Old 11-27-2015, 10:57 AM Thread Starter
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I've done some you tube surfing, and apparently what I'm after is a "french box" result.

i have made an octagon box and lid, and want an upstand inside the box to make the lid fit securely.
The box and lid are made, so I need to add a very thin siding inside the box.
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post #5 of 14 (permalink) Old 11-27-2015, 11:30 AM
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Why not resaw a thin piece on your bandsaw or table saw? You could then sand it to final thickness. I'm not sure why you want the inner wood to be so thin, it seems like it would be very fragile.
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post #6 of 14 (permalink) Old 11-27-2015, 01:03 PM
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I have made quite a few small boxes with a lift off lid such as you mention. You can make the lip to your own specs on a router table. You need to cut a rebate on the inside of the panels ; at least half the thickness of the panel, BEFORE assemble. THEN make the outside half of the cut at the bottom edge of that inside cut, after the sides are glued up and cured over night. I use a 1/2" straight bit to get a 1/2" lip on box and lid. I cut three sides on the outside of the box first. Before making the fourth cut, you need to insert 1/2" spacers into the other three cuts and tape them in place to hold the carcass solid while you make the last cut to separate box from lid. You might need to separate the top and bottom by hand @ the corners with a small saw blade. IF I have not explained this well enough, you can clear it all up by doing a search on YouTube for all sorts of demo videos. Wishing you lots 0 luck! Enjoy the sweet smell of the sawdust!!
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post #7 of 14 (permalink) Old 11-27-2015, 01:56 PM Thread Starter
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The box and lid are already assembled. i cant do anything to them.

This is yet another of my "learning as i go" episodes. The sides are 5mm thick beech. I might try to cut and sand some 3mm of the same.
i've seen very thin wood used, just wondering how thin it would be possible to go to and still retain enough strength. It only needs to stand proud by 2mm I think.
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post #8 of 14 (permalink) Old 11-27-2015, 11:28 PM
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Quote:
Originally Posted by sunnybob View Post
The box and lid are already assembled. i cant do anything to them.

This is yet another of my "learning as i go" episodes. The sides are 5mm thick beech. I might try to cut and sand some 3mm of the same.
i've seen very thin wood used, just wondering how thin it would be possible to go to and still retain enough strength. It only needs to stand proud by 2mm I think.
I would consider lining the inside of the box with as thick a piece as Practical. Orient the grain 90 degrees to the grain of the box sides for maximum strength. Orienting parallel is courting certain disaster.

My only thoughts on the subject. Good Luck.
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post #9 of 14 (permalink) Old 11-28-2015, 09:16 AM
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2mm or around .080 is gonna be tough to come up with if you're making it.

One option, as described above, is to use your bandsaw to cut a piece down and then sand...including the recommendation to install it against the grain.

Another option might be to find wooden blinds from which you might find a suitable thickness...

Maybe a hobby shop where balsa wood might be available (for building planes, etc...)

Whatever you find that thin I would coat it with an epoxy for strength.

All this failing, double tape the thinnest piece you can find and hand plane it down to size, then carefully separate the pieces...

I vote for using the bandsaw to resaw a piece down to size...

...good luck...

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post #10 of 14 (permalink) Old 11-28-2015, 11:06 AM
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It all depends on the wood you use for the thin liner in the lid or the box. Soft woods naturally must be thicker, like Spanish cedar,tough woods like oak, teak, hard maple, ash, elm,etc. can be thinner,like 1/16"=.063" . You can line the inside of the lid, or the box, take your pick.

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