57 - A Shop-Built Pin Router, страница 27
Cut Case Apart - At this point, kyou've got a case with no way to get inside. So the next step is to cut the case into two parts.
A table saw makes quick work of this. To start, raise the blade to cut through the thickness of the case (Figure 3a). But you're only going to cut through the front and back of the case with the blade raised this high.
The reason for this is to avoid "pinching" the blade when you cut the sides to split the case in two. So before you cut the sides, lower the blade to leave a thin membrane (Figure 3b). This keeps the case safely intact
As you can see in Figure 4, separating the lid from the case is just a matter of slicing through the membrane with a utility knife. Then just sand the edges of both parts smooth.
To ease the sharp edges on the case and make it easy to pick up, the top and bottom edges are rounded slightly. A round-over bit with a large radius makes quick work of this (Figures 5 and 5a).
Hinges - At this point, you're ready to add the hinges that join the two parts of the case together. The hinges rest in a pair of mortises cut in the lid (Figure la).
An easy way to do this is to use the table saw. To ensure the lid closes completely, adjust the height of the blade to equal the full thickness of the hinge knuckle (Figure 6a). Then just "nibble" away the waste for each hinge
(Figure 6). Note: Be sure to only cut through the back edge of the lid.
Once the mortises are complete, screw the hinges to both parts of the case. To ensure the hinge leaf doesn't bind against the lid, it's a good idea to ease the corners of the
FIRST; CUT THROUGH FRONT ANP BACK, SEE DETAIL 'a'
LOWER SAW BLADE AND CUT SIDES, SEE DETAIL V
mortise (see margin on page 26).
Latch - To keep the lid of the case closed, I added a decorative latch. The two parts of the latch are mounted to the front of the case with latch pins (Figure lb).
Install Tray - The next thing to do is install the tray. To make sure the bottom can expand and contract, I didn't glue the tray in place. Instead, I secured it with a few pieces of carpet tape.
Liner - At this point, I decided to do one last thing. And that was to flock the inside of the lid to match the tray. But with the case complete, that could get messy.
An easier way to accomplish the same thing is to flock a piece of posterboard instead. Then you can just press the liner into the lid (it's held there with carpet tape). Once the liner was in place, I slipped my caliper into its new home. ^
RELIEVE CORNERS OF MORTISE
A To prevent the leaves of the hinge from binding, relieve the corners of the mortise in the lid.
Va" ROUND-OVER BIT
MORTISE BACK OF LID ONLY
THICKNESS OF HINGE ~