I have made a lot of small boxes, and this has always worked best for me.
I always clamp the box and lid together, so as to keep everything perfectly aligned. I then use double sided Scotch Tape to adhere the hinges and latch correctly in their places. I then use the correct size of one of these punches to create a small dimple in the exact center of each of the holes to be drilled. Use the size punch for the size hole in the hardware. These punches aren't expensive, and should last forever in woodworking. Buy a better set if you plan to also use them in metalworking. This set is only $12.
www.harborfreight.com
I then usually use an ice pick to force a hole of about the desired depth. Doing this makes a good pilot hole for the screws by compressing the wood around the hole enough to make it stronger. If the screws to be used are brass, it's best to use a steel screw of the same size first. Then remove the steel screw(s) and replace with the brass screw(s). Brass screws break easily when forced into "too tight" holes. Sometimes I have even scraped the threads of the screws with some paraffin or candle wax to make them easier to install, but pre-threading the holes with the steel screw should eliminate the need for wax.
If you have used the double sided tape, remove it once you have used the steel screw to thread the holes and before installing the hardware with the brass screws.
I frequently make boxes with sides thinner than the length of the screws provided with the hardware. For these, I either buy the correct length screws for replacement, or I grind the tips of the hardware package screws flat at the needed length so they don't leave sharp points exposed inside the box. Adding a thin piece of wood to the inside back and front of the box to keep the screw points from being exposed is another possibility.
Charley
I always clamp the box and lid together, so as to keep everything perfectly aligned. I then use double sided Scotch Tape to adhere the hinges and latch correctly in their places. I then use the correct size of one of these punches to create a small dimple in the exact center of each of the holes to be drilled. Use the size punch for the size hole in the hardware. These punches aren't expensive, and should last forever in woodworking. Buy a better set if you plan to also use them in metalworking. This set is only $12.
Transfer Punch Set, 28 Piece
Amazing deals on this 28Pc Transfer Punch Set at Harbor Freight. Quality tools & low prices.
www.harborfreight.com
I then usually use an ice pick to force a hole of about the desired depth. Doing this makes a good pilot hole for the screws by compressing the wood around the hole enough to make it stronger. If the screws to be used are brass, it's best to use a steel screw of the same size first. Then remove the steel screw(s) and replace with the brass screw(s). Brass screws break easily when forced into "too tight" holes. Sometimes I have even scraped the threads of the screws with some paraffin or candle wax to make them easier to install, but pre-threading the holes with the steel screw should eliminate the need for wax.
If you have used the double sided tape, remove it once you have used the steel screw to thread the holes and before installing the hardware with the brass screws.
I frequently make boxes with sides thinner than the length of the screws provided with the hardware. For these, I either buy the correct length screws for replacement, or I grind the tips of the hardware package screws flat at the needed length so they don't leave sharp points exposed inside the box. Adding a thin piece of wood to the inside back and front of the box to keep the screw points from being exposed is another possibility.
Charley
