The lid and top trim are done and I think that this might turn out to be a tack trunk yet!
I tried to get the lid done yesterday but only succeeded in getting the lid sides cut. I needed to figure out a way to cut the plywood lid top to size which was just a little too wide for my table saw to handle so I stopped for the day to do some research in how I could accurately cut the lid top. I picked up today with cutting the lid top after I figured out a method that would work for my saw and completed the lid today as you can see.
I started yesterday by cutting the lid sides and top trim to size and cutting miter joints at each end. The lid sides and top trim are created from the same 1×8″ oak board . After cutting each side to length and cutting the miter joint, I ripped a 2″ piece from the board for the top trim, the rest for the lid side. I attached the top trim to the carcase using glue and screws.
In each lid side piece I created a dado to hold the plywood lid top. I also used biscuits in the lid side miter joints for added strength (It’s really nerve racking creating the biscuit slots in the miter joints as it’s very easy to punch through and ruin your work !). I then glued up the lid assembly and let that dry a few hours.
I couldn’t wait and needed to temporarily add the piano hinge and see how the lid would work. I was a little concerned about the weight of the lid which is why I purchased a good quality piano hinge. After mounting the hinge with a few screws I gave it a trial test and it works ! A little bit of adjusting is still needed and I also need to router some rabbits in the inside of the lid sides to add some clearance between the lid sides and the plywood carcase top edge trim but I think the design will work well.
Next step is to add the top edging to the center divider and mount the casters as the trunk is getting a little too big now for the workbench. I also need to start experimenting with some finishing techniques and start building the grooming tote and wrap holder. But before I do that it’s time for some golf in Myrtle Beach!