Then it gets the No 5.

And we go back and forth, testing the fit as we go.

Both ends.

Then I bump one of those ends against the far inside end, and make a mark.

And transfer a line that defines a rough length.

And I love my bench hook.

And my shooting board, with which I ill not only square the cut, but sneak up on the fit.

All for tonight. More later.

Thanks for looking!

So, once I have the piece fitted to the internal dimensions on the opening of the top....

...the two screws are so i can pull it back out. 🤨

I measure the depth and width of the box....

Place the fitted piece centered on a panel I cut to oversize of the box measurements I just took....

...slather on some glue....

...and clamp er down.

After the glue dried I glued the piece into the top of the box, waited for that to dry, then trimmed it to the box.

We are now skipping to the fun part.

Let's cut open the box!

So, make a mark about 2 inches from the top

Carry that all the way around, then I make a knife line that defines the cut.

I used a rule clamped in place so it would not shift, and cut that line all the way around the box.

This is coming along nicely, glad the weather is starting to cooperate.

Then it's time to get happy.

As I get near the end of the cut I use a clamp to loosely hold things together. I don't want the piece splitting right at the end; want a clean cut.

Tadaaaaaa!

10 minutes ago, DuckSoup said:

This is coming along nicely, glad the weather is starting to cooperate.

Thank you.

I am amazed at how long this project has taken. But I work on it a little at a time when time is available, so that makes it seem longer than it actually is.

Once the box is "opened" it needs to be fitted.

That involves taking a plane and cleaning the saw marks away, and squaring the edges.

This is done by using my 14" Jack, and using the longer sole to span two edges, keeping everything as level with everything else as is possible.

Keeping track of square.

This needs to be done on the lid as well.

Edited Saturday at 08:37 PM2 days by Handfoolery

After which I sit the lid on the box...

Examine the joint closely

And mark any areas where there is a variance.

After which I use a straight edge in those areas to better see what is going on....

...and then plane for correction.

then I use a board with 80 grit affixed to one end...

to span the distance and smooth things out.

This is done on both pieces.

...until the pieces fit with no gaps, and no rocking.

All for now. thanks for looking. More to come.

Edited Saturday at 08:59 PM2 days by Handfoolery

I have cut lids on table saw but with a hand saw is amazing.

9 minutes ago, Gerald said:

I have cut lids on table saw but with a hand saw is amazing.

Thank you.