Step 6: Sand the edges of the lid until it matches the rest of the box. You can either do this on a disc sander, or switch to a smaller detail sander like the one shown in Photo 6. Then sand the lid, bottom and face of the box up through the grits to 150.
Step 7: While the lid is still attached to the box, ease the sharp edges with a trim router and 1/2-in.-diameter roundover bit. Remove the waste in several passes of increasing depth to prevent tearout and burn marks (see Photo 7). Sand the routed edges to blend in the curved transitions, and smooth all the outer surfaces of the box up to 180-grit.
Step 8: Tap the lid free from the box gently with a rubber mallet. Make sure to do this over a padded surface so you won't damage the lid in the process! Sand the paper pattern off the rim of the box. Now, sand off the paper from the inner oval you cut in Step 1, and smooth its edges. This piece will become the lid's inner layer to help register it on the box. Use another copy of the paper pattern to trace the location of the inner layer on the lid. Glue and clamp the lid parts together (see Photo 8).
Step 9: You can choose any style of hardware knob for your box lid. A knob is also easy to make with your drum sander and a stick of 3/4-in.-square scrap. Here's how: draw two layout lines around your scrap - one measuring 1/4 in. from the end of the scrap and a second line at 7/8 in. from the same end. Install a 1-in.-diameter sanding drum in your sander, and sand a gentle concave between the layout lines. Do this on all four sides of the knob (see Photo 9). Try to match the sanded profile from face to face. Now cut the knob free from the scrap with a fine-toothed handsaw. Make the knob 5/8-in. long.
Step 10: We've provided a centerpoint on the paper pattern to help you locate the knob on the lid. Cut out the inside oval of the pattern, and lay it on the lid's inner lamination to mark the centerpoint with an awl. Drill a 1/8-in.-diameter, countersunk hole through the lid for a #6 x 1 in. wood screw. Then, drill a stopped hole into the bottom of the knob. Drive the screw through the lid to fasten the knob in place (see Photo 10).
Step 11: Topcoat the surfaces of your box with a finish of your choice, but leave the inside bottom of the box bare. That way, you can line the bottom with colored felt for a distinctive touch. Cut the felt to shape and glue it in place. When the glue dries, present your Keepsake Box to someone special who'll know just how to fill it!