This is a method I use for 2 piece wood patchbox lids that I thought I would share with all you two piece builders. The procedure is the same as far as basic patchbox construction. The assembly procedure is where I use a different method. I could never understand how you are supposed to glue two flat pieces of wood together without some way of indexing them to one another. They are going to slide and move all over not to mention the glue squeeze out, creating a mess at best. I recently finished one, and snapped some pics as I went. Hope this helps someone. TommyG
First the basics, fit your base. Make sure it is level in both directions.
Create a center line and a few witness marks on your lid. Set your lid in place. Add corresponding witness marks to the stock.
Next, layout and drill (4) 1/16” holes in the base. I put these about ¼” in from the ways and far enough in from the end as to not interfere with the end cap screws. The base is almost ¼” thick, I drill these holes 3/16” deep. Also, lay out a pencil line 1/8” in from each side and the front.
Take a parting tool(a small veiner would probably work too), and cut a trough following your pencil lines. This is a glue trough that will prevent any glue from entering the dovetailed ways.
Take some 1/16” dia. wire(I use welding wire), and grind a point on it.
Cut the wire to length so that you have the point plus 3/16”. You will need 4 of these.
Insert your pins into the base. It should look like this, pretty much only the points exposed.
Place your lid onto the base aligning the witness marks. Press firmly. You want to get the points to make good penetration into the lid. I avoid using a mallet as it could jump the lid out of position.
Now I remove the base/lid as one piece, keeping them together with finger pressure and slide them into the vise. Clamp the two together. You could use a hand clamp here also.
Remove from the vise. Separate the lid and base. You should see (4) holes where the points from the base penetrated the lid. Spread a layer of glue onto the base. I use Titebond 3.
Assemble the base and lid. Clamp overnite. Again, I use my vise, but clamps will work also.
Remove from clamping. See how it fits.
There is no glue squeeze out, but the glue will swell the base a bit requiring a bit of fitting. I cut my dovetails at 15˚ so I made up a 15˚ scraper with a polished base from an old sawblade.
Finished fitting with back plate. Ready to shape.
