I’ve done this numerous times over the years, w/variable success, but, right now, I can’t rember how it’s done. To make a “fitted “,interlocking lid on a box, the box is fully assembled. At that point, 2 cuts are made halfway thru w/a dado blade, one a the desired elevation on the box, and the second is made WHERE?? OR HAVE. GOT IT WRONG? IS THE FIRST CUT MADE ON THE INSIDE SEPARATE PIECES PRIOR TO ASSEMBLY?
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Here's how:
The first cut is made on the inside surfaces of the lid before the box is assembled, usually with a dado set, to get a groove that is just a tiny bit over half way through the thickness of the sides and about as deep as it is wide. The second groove is cut around the outside of the box after it is assembled with the same dado set up but further down the side from the top so that the lower inside corner of the inside groove just intersects the upper inside corner of the outside groove. The intersecting cuts will separate the top from the box and leave a lip on the inside of the base and a lip on the outside of the top that will interlock.
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