One of the easiest ways to install a plywood bottom in a box is by using a router table and rabbeting bit to route the space for it to fit. Unfortunately, most rabbeting bits are large and while they can be adjusted to cut a small rabbet for small boxes, that requires adding a large bearing which keeps it from routing into the corners.
Amana has made a small rabbeting bit that is perfect for making small boxes. It has a bearing diameter of 3/16 in. and routes a 1/8 in. rabbet, which makes it perfect for use with the Froebel boxes I'm making for gifts, 5, 5b and 6.
In
the photos above and below, you can see it in use. When the rabbet has
been cut, simply measure the inside space, cut the bottom to the same
size and then round the corners.For a single box, shaping each corner with a disk sander makes sense as it can be quickly done. In a production setting, many can be routed at the same time on the router table by standing them on edge and using a round over bit of the correct radius.
Make, fix and create...
