Tom,
I consider this a pretty easy piece actually. Starting with an 8/4 block of zebra. Square all edges and faces end ends. This is critical. Draw the box profile on one edge. On the bandsaw with blade square to the table cut off box lid and save. Then using a 3/8" blade cut the body profile with a smooth radius on the ends to the base on the inside cuts. Place the top on the body and scribe the wenge sides to the profile. Cut 1/16" over the line on the bandsaw. Now you have the sandwich. Start smoothing the box interior. I have a 2" dia. Grex pnuematic ... sand to 220 grit. Hand rub with soft abrasive . Same on underside of box lid. This is really your only chance because once assembled its not possible. Glue the base to the sides using the top as a non glued spacer in the package. Let dry. With the lid in the assembly sand the exterior until it is all flush and the shape you desire. Carefully align the door and drill the holes for the brass rods using a drill press... drill into the lid. If you are off.... you just ruined the box! Test the fit with short rods inserted. Use epoxy to glue rods. Once dry sand the exterior, oil and finely polish.
Last edited by Mark Singer; 02-21-2009 at 9:34 AM.
"All great work starts with love .... then it is no longer work"