Cont....
Now that the box is assembled and the doevtails flush sanded its time to start the "finish" process. With your orbital sander prep the outside of the box with 100 grit sand paper. DO NOT SAND THE VENEERED LID, just the main case and the lip surrounding the veneer. Apply your first coat of sanding sealer. Wait for it to dry...
Now sand the same areas as before with 150 grit sand paper. Apply a second coat of sanding sealer and wait for it to dry.
Just a little more sanding to go. Once the sealer is dry sand the box with 150 grit sand paper. Now choose which side of the box will be the BACK, where the hinges will be installed. Mark the top and bottom of the box along the case with a light, but distinguishable "B" to be sander off later. Use a pencil. This will make assembling the top with the bottom the right way since the grain may be a little hard to match up on an unfinished case.
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Take your top off!!! This process may seem difficult but if the steps are followed you will achieve success and eliminate some additional sanding and fine tuning of the lid fit.
Set the table saw fence the correct distance from the blade to split the upper dovetail almost in half. Leave it off center about a 1/32" with the larger portion to the case, not the lid. I will explain why later.
Now set the blade height as close to equal to the thickness of the side of the case. You want to just cut through the thickness of one of the box sides without going too deep. Now run the box through the spinning blade with the top of the box against the fence. Do this for the "long" sides of the box only. You will end up with the two parrallel long sides of the box cut and you should be able to see light throught the box when viewed from the cut side.
Now, WITHOUT MOVING THE FENCE, lower the blade to just under the thickness of the box sides. Run the box through the saw on the two remaining uncut sides of the box. The lid should remain attached to the box, but just barely. This is done to get a consistant cut without the hassle of keeping to case from binding on the saw blade.
Your lid is now cut but not seperated from the box. Get our your sander and get ready with your 220 grit sand paper. Find the back dise of the box with your label "B" and sand it smooth. This is done now because it is rather hard to finish sand around the hinge hardware later.
To seperate the lid simply get out your utlity knife, and with a few light passes, cut off the lid. I prefer cutting flush on the lid side leaving the "extra" on the case. Once the lid is seperated reset your table saw fence to cut off about 1/32" of the box rim when the box is oriented with the bottom against the fence. Run it through the saw for each side. This will do two things. Get a consistant edge for the lid to sit against while removing any "burn" marks that may show up from the initial cuts to remove the top.
One final set of thing to do befor attaching the lid to the case. With the orbital sander with the 220 grit still attached, quickly give the box lid and case surfaces a quick final sand and test the fit. Make any adjustments now if there is a corner that wont fit flush by sanding down any high spots. Remember to match up the "B" sides.
