Fitted Top Box

For this style box you will need to make the sides out of wood that has been grooved to match the bottom and top panels. You will need to have a good idea of the size of your rock and plan the top so it is just a bit smaller so you can trim the edges of the rock to just fit.

Note that the joints in this box are like those of the slide box, so look over those instructions to see how to make the slots and rabbits.

Some care has to be taken to get the dimensions just right. If your box is a bit too big it can't be fixed to accommodate a smaller rock.

Before you glue the box, clamp it together and double check your dimensions. In this case the width was fine, but I had to make the rabbits a bit wider to shorten the box some.

Now that you have a box with a lid and a bottom you will need to cut a separation slot. Set the table saw blade to just under the width of the side boards.

Then, using the thinnest kerf blade you have, carefully slice the top off using the fence as a guide. Don't wiggle this or you will have an uneven joint that will be difficult to iron-out.

When complete, use a trim saw to cut the box apart and then a chisel to remove any burrs left from sawing.

The joint will still need work as there are always problems using this technique getting the final cut corner perfectly flat.

Use a flat piece of sandpaper glued to a piece of MDF or smooth, flat plywood to sand each side flat. This may take some work!

When the top is ready , cut strips of wood to act as guides to fit the top into the bottom. These should stick out at least 1/4 inch or so. Glue them in and the sand the edges with a chamfer so that it will slide into the bottom more easily.

For softer woods I often round or bevel the top edges. Soft woods do not hold their edges well, so, rounding corners takes away this liability. I use a hand-held router, but a table router could work well or a hand sharp hand plane if you want a bevel.