nova wrote:
are you able to bevel the inside edges of the box sides? If they're all at a 45* angle and cut to the right size the parts should all just fit together perfectly with little to no gap.
I tried going with the idea of putting a 45 degree router cut to "fold" the box, but that resulted in more time and lots of line up issues. For the box I'm just running strips on my band saw and then running those strips again to cut perfect squares. Then I bring the fence in a little to cut a touch more plastic off to get the right measurements allowing a perfect box. That part is actually not much of a problem.
What the real problem is, it's when I'm laying the image on the box. These images are a rather high quality thick material. I'm not saying that to sound like "yeah this is so great, the material is amazing". It's just that it is what it is and it makes it harder to perfectly lay it out on the box. Over lapping isn't something that can be done unless it's done so that a seam isn't showing.
They ideas I can come up with are:
* Make the images smaller than the actual size of the box so that the image doesn't go all the way to the edge.
* Figure out a way to overlap the images where no seam is showing and it perfectly is laid out. This could be done by having the front back and sides as a solid image it's self that wraps around, but then there still the top and bottom to worry about.
This doesn't even include the idea of having opening boxes. I was going to do that idea, but now I don't know. It may not be necessary anyway, but still it was a thought that would have been neat. I have 2 other cubes built that I'm testing ideas on. I figure one idea should work.