It's hardware time! This is a true sign that we are getting very close to the finish line. In this part I will be installing the hinges, the chains etc. and I will also start construction of the upper trays.
I usually cut the shallow mortises for the hinges using a hand held router and then square the lines with a sharp chisel. This time I'm trying something new. I'm using a router table with stop blocks on either side of the router bit, to control the length of the cut, which precisely fits the hinge leaves.
Notice that the router bit leaves a round corner? I simply use a chisel to square the corners to fit the hinge better.
I also went ahead and installed the chain to keep the lid from flopping backward. Since the box will have an upper tray, I also attached some wooden risers on the interior of the box. Notice the rabbet cut on the riser on the chain side of the box? This rabbet will act as a stop, which will prevent the tray from sliding side to side and hitting the chain.
The trays will have simple mitered corners with splines for reinforcement. At the table saw with the blade tilted at 45 degrees to cut the miters.
A closeup of the grooves I cut to house the bottom panel of the tray.
Please join me next time for part 10 when I will be constructing the dividers of the trays.
Thanks for looking!
Roshaan
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