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Rabbet Box Project

  • Materials ¾” plywood 10”x20” piece or scrap equivalent.
  • No nails or screws will be used in this project

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Steps 1-2

  1. Use a piece of Graph paper to draw a 3d plan of your project.
  2. Sketch your cuts on your piece of plywood.
  3. Show Mr. Gary your plan before you make any cuts.

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Cut List (3/4” ply )

(2)3”x9” sides

(2)3”x6” ends

  1. Top cut to fit approx.

6”x9”

Bottom of the box is 3/16” thick Plywood scrap.

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Step 3.

  1. Cut box parts starting with a 10” crosscut using the sliding table saw.

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Step 4.

4. Rip 4 pieces for your ends and sides to 3.”

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Step 5

5. Cut ends and sides to final length using the miter saw.

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Step 6

  • Cut Rabbets on each end of 6” pieces on the dado saw.
  • Depth of rabbet is always ½ the material thickness.
  • Width of rabbet is equal to the thickness of the material.
  • Be sure to test setup with scrap piece.

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Mr. Gary must help you the first time!!!

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Step 7

  • Cut groves to accept the 3/16 bottom using the tablesaw.
  • Remove tablesaw guard and put on riving knife.
  • Set blade height to ½ the material thickness.
  • Set fence at ¼”
  • Make one pass on each side and end. USE A WOOD PUSH STICK!
  • Tap the fence 1/16 away from the blade and make additional cuts until your bottom fits the grove.

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Step 8

  • Dry fit your box and measure for the bottom.
  • Cut the 3/16” bottom on the tablesaw.
  • Dry fit and clamp all five parts of your box and show Mr. Gary.
  • Glue up your box. You need 3 F clamps.

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Step 9

  • Once box is glued up, remove clamps.
  • Measure the dimensions of the top of the box
  • Cut the top to exact dimensions using the tablesaw.

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Step 10

  • Set the dado saw height to ½ the thickness of the top.
  • Set the fence (with sacrificial rabbet fence) to ½.” Cut all four sides of the top. Using wide orange push block.
  • Check the fit. If it’s too tight, tap the fence slightly away from the blade.

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Step 11

  • Lightly sand all surfaces by hand with fine sandpaper.
  • This is a good time to use the laser engraver or CNC machine to add a design to the top of your box.