Help with routing a box from a solid block - Router Forums
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post #1 of 16 (permalink) Old 10-11-2014, 08:16 PM Thread Starter
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Default Help with routing a box from a solid block

I do hope this is in the right place. If not please move to the correct spot.
My plan is to build a box approximately 4"x1"x2"with 1/4 inch sides and bottom. I am looking at a 1/4 inch sliding top using a dovetail to slide the top in and out.
I watched the video on building a template and that is done.
I have a Porter Cable model 5372 1/2 inch router.
My first question is am I going about this the correct way or is there another solution?
What bit is the correct choice to get this done?
I am new to the router guide bushings so what do I need to pick up to get this job done?
I have a number of different hardwoods to chose from but that question will come later.
Thanks for any help!
mark
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post #2 of 16 (permalink) Old 10-11-2014, 08:30 PM
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One of your problems will be the sliding lid. If you are making the box from a solid block you can't rout the corners out square with a round bit. You will be limited by the radius of the cutter you use. Had you considered this?

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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post #3 of 16 (permalink) Old 10-11-2014, 08:43 PM
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What Chuck said, also, you might be really really unhappy if your box starts splitting after machining,,,you're potentially releasing a buildup of stresses in the wood. In other words, the grain won't be running ideally in all planes.
One of those situations where your choice of wood species might be critical. If it's just a fun thing, consider Yellow Cedar for your first try. It's pretty forgiving to carvers.
https://www.google.ca/search?q=Yello...w=1120&bih=537
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post #4 of 16 (permalink) Old 10-11-2014, 08:46 PM Thread Starter
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My thought process for this is to set the dovetail up on a router table set the bit lets say 1/4 inch from the fence and run the box thru the router. Do this on both sides. Route the material on the ends between the dovetails. I think this will leave me with an opening that the top can slide thru. I could be mistaken. And now you do have me thinking...
Thanks for the help. I really would like to tackle these sort of problems before I get started.
Thanks again
Mark
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post #5 of 16 (permalink) Old 10-11-2014, 08:48 PM
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Apparently they go for big bucks!
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post #6 of 16 (permalink) Old 10-11-2014, 09:10 PM Thread Starter
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Thanks for the help. Would much rather be disappointed now than later. I am running the blocks thru the table saw now cutting a 1/4 inch slice off the bottom, cutting the inside of the box out with a jig saw and gluing the sliced piece back on as the bottom now. I thought a solid piece would be nicer. But if it is not going to work I can start rethinking this.
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post #7 of 16 (permalink) Old 10-11-2014, 11:40 PM
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You could make an opening on one end and a dovetail groove down the sides and across the other end but the corners will be rounded. You could round the end of the lid to match but it will be a bit tricky to keep the dovetail around it uniformly. That's one issue you'll need to consider with your build, how will you do it and will it be worth the effort.

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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post #8 of 16 (permalink) Old 10-12-2014, 10:45 AM Thread Starter
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I guess I am kind of confused why the box will have rounded ends. I am only going to route the inside of the box. The outside will be cut on a table saw and ends cut on a radial arm saw.
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post #9 of 16 (permalink) Old 10-12-2014, 10:48 AM Thread Starter
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I will drill out the four inside corners which will allow me to make a smaller radius than that of the router bit.
Thank you for the replays. I want to think this thru and I really appreciate the input.
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post #10 of 16 (permalink) Old 10-12-2014, 11:18 AM
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No prob. I was suggesting you could round the corners of the lid to match the radius of the dovetail cutter. This is a similar problem to making mortise and tenon joints. If you use drills or router bit to make the mortise the corners will be round. If you want square corners for a square tenon you have to chisel them out. Or, you can round the corners off the tenon to match the mortise.

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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