I finally finished building this crazy pantorouter demo machine
and now I gotta ship it, But because I spent so much
time on that machine, I haven't had time to build
much else. So in this video, I'm just gonna
build a shipping crate for it. And, I've already cut the
plywood for this thing. But, because this stuff
is only about 1 centimeter thick, I'm gonna
reinforce it in the corners with this,
which is just a 2 by 6 that I ripped into strips.
Now, these strips will reinforce the edges
like this, and just to make it sturdy,
I'm gonna join the corners, with box joints.
I cut the box joint with my trusty old
box joint jig. And, to make it go faster,
I stacked 2 blades in the saw, so I get a wider curve.
And, I worked out, where on the gear,
I have to make the second cut, which is where
this piece of take is, so let's get cutting.
The meeting pieces need to be 1/4 inch offset
and since I do two turns of this gear for
each finger, I'm just gonna start this one
one turn offset.
Because my work bench is presently occupied,
I'm gonna do this glue-up on the table saw.
The frame's attach to the side panels, like this,
except to attach it, I have to flip it upside-down.
The bottom overhangs the sides a bit here,
and I don't want it getting caught on that edge,
so I'll bevel that, and I think that's easiest
while I still have it up on the table saw.
To help position the lid, I'm gonna put this cleat
on the inside of the lid, like this.
Now, I'm gonna put another cleat on the other side
of the lid. But, how to line that up?
I can't really do that from the inside.
So, I thought of a trick. I'm using a pair of wedges
to try to hold this thing in place.
So, I added this tab and a notch here,
and that makes sure the lid only fits on, one way.
Well, I managed to get it into the shipping crate,
just barely.