Spot Welder Box

I needed to tidy up my battery repair gear so i made a box to keep everything in
I found two clean Euro pallets  1200 x 800 being tossed so I "rescued them"

If  you wondered about using pallets look for these details to guide you.

I dismantled them and managed to reclaim about 50%

The particle board blocks and bases were sawn off and dumped leaving enough to keep me busy.

Set to work Jointing them.

and just about all were usable

I decided to thickness them to about 16 mm

This provided enough stock for the Frame and base

The remaining top pieces I will use for the Lid and internals
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The frame concept

The two with knots will be the ends and test jig for profiling

I hadn't used my Gifkins Dovetail jig for ages so it got a workout

First up a test fit piece was made

used for the profiling and biscuit alignments

Happy with that the frame was dovetailed.

Biscuited two pieces together for the base

Then started on the lid
At first I thought about a cross section top

decided it would be all too much work and decided to think again

I had three pieces suitable so I went with them

Less process and it should work OK

I though I would have less cupping and stabilising defects that way.

After making a fitting I didn't have enough material to saw in a raised panel so it stayed flat
Glued up the frame and base, then saw raised profiled the test piece at 5 deg

I found I would lose about 50% of my dovetail joint if I stayed at 5 deg so I reduced it to 2.5 Deg and a 45 mm height

Sanded and trued everything on the frame and set to work making mock raised panels

set up a sacrificial fence to maintain alignment

the raw finish

final concept

Lotta fun and skill building too.