How to Flatten and Size the Lid

In this video, I discover that the lid of my box is incredibly twisted. But instead of re-doing it and pretending nothing happened, I show you how to go about fixing the problem. In addition, you will also learn how to accurately thickness and size the lid to fit within the box.

This lessons objectives:

  • How to diagnose twisting and cupping
  • How to flatten the lid
  • How to thickness the lid
  • How to fit the lid

Side note and spoiler: If your lid is particularly twisted/distorted and you cant be bothered to fix it. Simply cut the lid along the joins, re-plane the edges and glue it together, and hope for a better result!

Obviously this step is far easier of you have a tail vice on the workbench that allows you to clamp the timber in all sorts of orientations. The doe's foot that I demonstrate in this video is a great alternative, although there is another piece of workshop equipment that can double up as a tail vice and easily be retrofitted to most workbenches.

It's called a Veritas Wonder Dog and only requires a hole that is 3/4″ in diameter. This is 19mm for us metric folks. If you are working on a thinner workbench, a Wonder Pup is a better option.

Keep in mind that the height of these is not adjustable meaning they may sit proud of the lid while you work on it. You can get around this by sandwiching your component between two pieces of thinner material at either end, then clamp these.

They are incredibly versatile for all kinds of operations, from both hand tools to power tools. I used them extensively before making my Roubo Workbench and they got me out of a lot of sticky situations!

The Veritas Wonder Pup

Supporting Material

Click the images below to see supporting material helping you with this part of the project.

How To Sharpen a Plane Blade

You really do not want to be getting tearout at this stage of the project, so using a sharp blade at this stage is incredibly important! If you need a reminder on how to sharpen a plane blade, including producing a cambered edge, this lesson will help!

How To Setup a Plane

There's no point in having a sharp blade when your plane is setup to produce thick veneers! It's important to take off small amounts at this stage to both prevent tearout and be precise with our material removal. This lesson shows you how to do that.

How To Use a Plane

This is another one of those topics that people feel there isn't much to learn. However once you break down the process of chiselling into subjects such as viewing angles, power transfer and chisel geometry, you open up a whole new can of worms. This is well worth viewing.

Have you got the plans yet?

Package includes working drawings, a cutting list, and a 3d SketchUp model!

The Student Series

Want to see another beginner make this project before you? It's a great way to scope out any mistakes before you make one yourself!

Opposing grain direction on the box lid – 4:28

Removing more tearout– 7:00

How to use a high angle blade to remove tearout – 13:05

Using candle wax to make planing easier – 13:49

Removing tearout in small patches – 14:16

Using a cabinet scraper – 19:05

Overview – 21:50

Robs suggestions – 24:00

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