Hmmm...blades and chippers are a very TIGHT fit onto the tablesaw's arbor...but..

Needed to cut a 5/8" wide dado....except the insert will NOT fit back in...almost out of thread on the arbor, too 2 blades + 3 chippers = 5/8" width..so, since the dado is on the end of the part..

I slid the fence over until it just brushed against the blade..then I used the mitre gauge to push the parts through..

A bit rough cutting..and after a dry fit...

had to move the fence a half blade wider...

 

next, each side of the box gets 2 grooves milled....figured I just remove the 3 chippers and go with the 2 blades..

reset the fence a bit...left the height alone...and..

I soon had 8 grooves made...

Stay tuned...

Mk2 MOD4 Eyeballs were used...trying to draw up a plan of sorts..full size, this time..

One of the few times I'll do tails first...how it looks like on paper..and how it gets sawn..

I might need a bit more practizing...then transfer this over to lay out the pins..

2 half Pins, and 2 Full Pins...and lot of saw work, chisel work and some cussing....

Biggest reason I do NOT do tails first...they tend to come out a bit too loose...

At least the grooves line up...

1 corner "done", 3 more to cobble up...

This MIGHT take a while..

Stay tuned...

Nice work, time consuming but worth the result.

Following closely. Love the design on the box, the previous 2 turned out great. Back to the design, it looks old. Any info on origin, style, original purpose or use? It almost looks like a French design or something. 

Looking great so far Bandit.

The Design is what Paul Sellers called a Small Keepsake Box....not sure where he came up with it.  

 

Bandsaw work, today...

Seemed to come out a little bit better..and quicker

 

Doing the pins, however...was back to a handsaw, a chisel or 3, and a Warrington Hammer...

Takes a while, by hand....spent 2-1/2 Hours IN the shop, today..( on a MONDAY?)

Finally got all 4 corners done did..

And did a full Dry Fit...can not glue this out, yet....I have to mill the 2 panels to fit into the grooves, and yet overhang at the top...

 

original version had a Divider inside..

Sits in a stopped dado....not sure IF I will add that detail in...yet..

 

Once the panels are fitted up, then I can glue the box up....when the box comes back out of the clamps, a plane and a saw will do the rounding part...

Tails that stick out will get trimmed back...

Then, I get to saw the lid off of the box...fun...

 

Stay tuned,

Shop has very few jigs in it...used one this morning...

Just 3 strips of scrap, and a handful of screws..sized to fit over the rip fence..

And slide along the top of the rip fence...job is to hold a part vertically..

With 2 c clamps..

All I have to do is just guide/glide it along to make a cut on the end of a board..

usually not needed for the horizontal cuts...

The 2 panels needed a groove all the way around the edges...

There was one more cut to make...as I need to undercut one side of the panels' grooves...so that they don't bottom out in the grooves in the box..

 

Then, the Boss decided she had errands to run...

 

Stay tuned..

Can this be glued up, yet/

Not exactly....I need to hand plane each side into a curved cross section...

 

Stay tuned..

Amazing work, Steven!

Needed to do a dry fit, this morning...

Grooves needed to be a hair deeper, panels needed to be 1/8" shorter.

.

I needed to mark up where to stop the hand planes at...."Line to Gain"?

Need for this mess to "Un-arse this AO"   so I could jig up the first panel

A little overhang won't matter...start with..

A long plane, tilted just a hair....working my way towards the center of the face..

needs a wee bit more at one end..then finish up with a smoother..

Almost there..

Note the shape of the pin on the left...

I get done with one edge, rotate the part 180, and repeat..double check the fit..

Still needs a hair more on the upper part?  

Managed to get one end and one side of the box rounded over...Laundry Details were making the shop a bit too toasty to be doing this sort of work..

 

Was getting a bit of a tired, crampy , sweaty mess...so..

Might need to be swept up a bit?

Could be...

Stay tuned...🤠

This is one cool project Bandit.

I can't do a full dry fit with all 6 parts...so...

Might try for a glue-up tomorrow?

Got the last 2 sides done, after the Laundry was done...

Tends to make a big mess on the floor...

Stay tuned...

Is it me or is this project moving along rather quickly??

Have to custom make a batch of cauls...to fit the curved sides better...have everything ready to go...and try to do with 2 hands what it should take with 6 hands...before the glue sets up....I imagine there WILL be cussing involved?    

 

Film @2300hrs..I hope

Stay tuned...

Well.....THAT was fun....6 parts...vs 14 clamps and 6 cauls....2 cracks repaired...letting the mess just sit there for a day...

Film in a weee bit..

.

Fancy Cauls at the ready...just pine..

That be either the top or the bottom of the box, not sure yet

14 clamps...6 cauls...2 acid brushes to spread thing out..glue bottle nozzle had to be cleaned out first..

letting thing sit right there for a day...

Stay tuned...

1 hour ago, steven newman said:

14 clamps...6 cauls...2 acid brushes to spread thing out..glue bottle nozzle had to be cleaned out first..

letting thing sit right there for a day...

S

 

I'd have used every cuss word I know and probably made up a few along the way!

3 minutes ago, lew said:

 

I'd have used every cuss word I know and probably made up a few along the way!

That's saying something coming from a Sailor😆

There is an issue....when the originals were made..they were 4" tall...the new one is 7" tall...Problem?

Once the box is out of the clamps and cleaned up...I need to saw the lid off..

 

The vise only opens to 6"

Might make things a bit rough to do the saw work?

Trying to come up with a way to hold the box to saw it...

So the lid can be sawn free...

Also, I did not do the dado for the divider....thinking a simple lift out tray would work better..

 

 

stay tuned...

 

Out of the clamps, nothing flew apart..

Trying to work my way around the "block" here..

getting there...

Cutting gauge, NOT a Marking Gauge...

That seemed to want to follow the grain...

Goal is to FOLLOW that Line...but..

This saw wasn't working out...we have ways..

Work Holding?

One clamp in the Bench Vise..another around in back,,clamped to both the box and the bench..plus a keeper holding down the other end of the back clamp...

next up?  a bit of work with a plane or 2...to level out the saw cuts

Again, a clamp in the bench vise...and...

A "plane Stop" around in back...plane moves at a diagonal...bridging between several edges at once...making a circle trip...

I can set the box down to check progress..

Then, flip things over, and level the top of the box....and keep checking..

Couple of high spots yet,,,almost ready for hinges?   I also have to plane the sides where the lid meets the box..making up for the saw kerf...

 

Stay tuned...

 

 

You are a braver man than me cutting the lid free with a hand saw! After planning to even things up I would have ended up with something the size of a cigarette pack!