RTA 300 Router Table Review - Carba-Tec

Pre-Cut Box Kit Project
Split Lid Box
These boxes may be dovetailed on a dovetail jig such as the Leigh Jig, or alternatively
they may also be hand-dovetailed, box-jointed, mitred or joined through
other rmeans. Just be aware that if you choose other types of joinery for the project
you might need to adjust the panel sizes.
PACKAGE CONTENTS
In your pack of beautiful Western Queensland Hardwood timber you should
have:
2 of 250mm x 108mm x 10mm (Sides)
2 of 150mm x 108mm x 10mm (Sides)
2 of 250mm x 140mm x 8mm (One Decorative for lid and one for base)
2 of 240mm x 70 mm x 2mm (Linings)
2 of 140mm x 70 mm x 2mm (Linings)
ALL THE TIMBER IS KILN DRIED, CUT TO SIZE AND SANDED TO #150 grit.
Step 1: Layout
A feature of this timber is that it has been end matched, being sawn from the one piece.
You can therefore 'wrap' the timber around the box, matching the grain. Lay out your box
and label the components clearly. It is also wise to label the corresponding edges to avoid
confusion.
Step 2: Dovetailing
**REFER TO YOUR DOVETAIL JIG INSTRUCTIONS ON HOW TO CUT DOVETAILS.**
On a Leigh® Jig, arrange your dovetail guide pins to suit the dimensions of the timber
being machined. The dimensions used in these kits will also suit the Carba-Tec EuroJig®
without modification. A backing piece is recommended to avoid chip-out when using dovetail
jigs. Masking tape applied to the timber where the dovetails will be cut prior to machining
will also help to prevent this. We recommend the use of CMT® spiral router bits for
this task, as they will provide the cleanest cut.
NOTE - If you are unfamiliar with your dovetail jig, it may be wise to machine some material
to the same dimensions as your box components and cut sample dovetails to check
the fit and the layout first.
NOTE - This box is dovetailed and glued before the lid is cut off. You will therefore need to
make the dovetail pin you are going to cut through, wider, by the same amount as the kerf
of your sawblade or router bit. This will create uniform pin sizing overall. *This cannot be
done on fixed template dovetail jigs such as the EuroJig®.*
Step 3: Cutting the Grooves for the Top and Bottom
Dry assemble the box and hold it together with masking tape. Set up a 4mm slot cutter
with a bearing in a router table. You will want a depth of cut of about 5mm. Run your
groove around the inside of the box top and bottom while it is assembled, leaving a space
of about 5mm from the edge.
NOTE - This will leave a rounded cavity in the corners. If you don't have a router table you
can cut this groove on a tablesaw, with the box disassembled, but you may need to plug
the ends of the dovetails where the blade comes through.
Step 4: Rabbeting the Top and Bottom Plates
To fit the top and bottom panels into the grooves you will need to reduce the thickness of
the edge down to 4mm by cutting a mould around the outside of the top panel, using a
cove cutting bit, dish cutting/bowl & tray bit or similar (CMT 851-502-11 is ideal). For the
bottom panel a rabbeting bit can be used to create a tongue around the edge of the base.
You may also use the same cutting bit as per the top if desired.