How to Make a Box
Boxes come in all shapes and colors, and for any purpose. Today, Bob Rosendhal shows us how to make a box with a lid, using a router. Any box consists of 6 pieces—the top and bottom piece, two sidepieces, and two end pieces.
For this project, put a rabbiting bit, 3/8 of an inch wide and about ˝ an inch high in the router. Pick the face side for all pieces and mark a quick X on all of the pieces. Place your fence, hold side down to allow debris to move out and clamp on end. Isolate the bearing by lining up the piece with the bit. We don’t want to come into contact with the bearing, so we want to board to just barely touch it. When you have it in the right place, put the second clamp on the fence. Adjust slightly, if needed, with a hammer. Set your depth to 3/8” depth.
Before cutting, be sure to test height with a scrap piece of wood. The height should be no more than half the thickness of the wood. Always cut on the end grain first, come up the side with the grain, cut across the grain at the top and work down the other side with the grain. Do only the ends on the sidepieces, while doing all sides of the top and bottom pieces. Do not do the end pieces just yet. To check if you did it right, place all pieces together to make the box. If they line up right, you did it right. Set these pieces aside.
Change your bit out to a 3/8-spiral bit. Put a brass ring in first, so the bit will fit tight in the hole. Turn over the fence with the hole on the top and the straight edge in against the router. Run a groove on the inside of the sides and ends. Make sure your face side is facing up, while working the inside of the box pieces. The height of the groove should be the same depth as your rabbit cut you made in step two. Check box to make sure the grooves line up. You are almost ready to glue it together.
Mark the spot on the outside where the groove is on the outside. Glue the box together all the way. Let dry before moving on to the finishing step.
To finish the box, cut a groove on both long sides, matching where the groove on the inside was before gluing the box together. Before doing the end pieces, tape a wood pin in the groove on either side, or this will not work. Cut the end pieces and then remove tape and wood pins. Take off the lid. And there you have a box that can be decorated however you wish!