Video 4 – Sanding and rebating the box sides.

Now that we have flattened the box side, we now sand the inside face of the box. I start with 80 grit, then move onto 120, 180 and 240 grit.

I have been asked what do I do if I don’t have a linisher. Before I had the linisher, I use to use this system where I glued sandpaper to a piece of melamine. Yes it does take a lot longer, but the best you can with what you have. I clamp the melamine onto the bench and work my way through the grits.

Next step is to put a rebate into the inside face of the box. This rebate is to hold the solid base.

We want the rebate 5mm above the bottom side of the box side. I use a 1/4″ rebate cutter on the router table. Make a test cut, and if you happy with that then cut all your box sides.

After making the rebate, we move onto the miter saw. My miter saw is fixed in place with the blade fixed at 90 degrees.

When I want to make a miter joint, I use a miter jig rather than move the angle of the blade. I use a home made jig to make these cuts.

Before we start cutting the batch, we always make a test cut on a scrap piece of MDF to ensure the jig is still true. After you have confirmed that the jig is true we can then go through and cut the batch.

Next video – Cutting the box sides, base of the box and gluing the box.