In the thread about Maths being everywhere I was disparaged for saying that I would use a milling machine to do the job. I also mentioned that I was designing a box with a secret catch and Adam hoped that that turned out OK. Well - I've nearly completed that box - machined 90% on the milling machine (just a small bit of turning hinge pins and bushes on the lathe) so thought that you may like to see why I find machining exotic timbers on the mill easier than trying to use 'normal' saws & chisles which are far too large.
This is the 'dry' assembled box as yet without the catch mechanism - you'll soon apreciate why!
Overall width and depth is 50mm and the height is 30mm. Top, front & back are Olive and the sides are Rosewood.
The 'hinge' is created using 2.7mm Ø Brass bushes with a 1.6mm Ø bore inset into the lid and 2mm Ø St. Steel pins in the back turned down to 1.6mm 'free fit' to the bushes.
The base is 1.5mm Oak ply.
Now, the interesting part is that there will be a Brass sprung catch inset into the front which will be operated by pressing a 3mm Ø ebony button on the left hand side. There will be 7 other 'false' Ebony buttons, making four 'dots' on each side. Here are some photo's of the catch - one with a 5p coin to show the scale.
The left image shows it un-assembled but with the actuating rod in place - that is a 1mm Ø St. Steel pin. It's difficult to see, but the body is a dovetail. The next image may make that more obvious.
The hole on the left hand side will position a 3mmØ spring 2.5mm free length which will keep the lid closed until the Ebony button is depressed - travel will be no more than ½mm.
Fitting the catch is my job for tomorrow