Click here for parts one and two!

Step 1

On Friday I reprogrammed my toolpaths and cut version 2.0. The only part from the first design can be used as is, is the base. That meant I had a lot more room to play with on my 12x12" board, albeit with slightly less material optimisation.

It is sexy.

Step 2

Then I cut and sanded off all the tabs.

The last machine job for the main box was to cut joints in the end pieces. Because I can only rout one face using the ShopBot, I decided to use it for the inside. That kept the the divider slots and base recesses uniform. Then I carefully ran the ends over a table saw using multiple passes until I reached the desired dimensions.

In the last photo you can see the length dimension I worked to. The shoulders of the end parts had to line up perfectly with the shoulders of the central divider.

I packed up and went home.

Step 3

Now the real game begins. No more computers and machines to help me. It's all sweat, blood and handtools.

Here are the two sets side by side. The left set is the one I'll use.

Here's a close up of the main issue I found with the sliding lip. You can see the one on the right is deeply fragile, whereas the one on the left has deep integrity.

There are three totally unsalvageable parts. I put them in the circular file and wrapped up the rest for use maybe one day in the future.

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At this point you might be wondering, why is this taking so long? Show me the box! Jesse Pinkman on Breaking Bad made a box in like two minutes.

Well look. TV is lying to you again. Real life is different. Ok. Good. Moving on.

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Step 4

The most laborious part of this project was fitting the joints. While my ShopBotting was precise it can never be perfect.

I spent a good four hours yesterday sanding, knifing and chiseling the tongues and grooves to perfection. Here's a crap time-lapse.

This gap is approximately a dozen thousandths of an inch wide, which is a measurement that I never thought I would think or type. America is one of only three countries that still measure shit in inches. The other two are Liberia and Myanmar.

The central dividers have a different type of joint—I've no idea what it's called—which is a tight yet workable fit. I could have made the notches slightly wider but maybe it's better like this. I will simply mallet the parts together before assembly. Hopefully...

Step 5

My final task yesterday was something fun.

I went to my local Home Depot to choose a stain. I want something darker, less arresting than the natural bamboo colour, but still light enough for a nice contrast with the wenge.

I licked my finger then wet a corner of the lid for reference. (Wenge is toxic so don't lick it directly!) See the difference in colour!

Golden Pecan 245 it is.

Thanks for reading! As always I'm happy to take questions.

Part four is here!