There's a gap between the lid and the box of about 1/32" at it's greatest point. I think it's because of the hinges or maybe it's just because the lid and box weren't subjected to strict QC (It's a cigar box after all!)... But I'm looking for any advice I can get in making the box fit together at little tighter -- using only hand tools.

I was thinking of taking the hinges off just to see how the two parts fit together without the hinges. And then I might have to nail or screw  or glue the two parts together.....?

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Leave it alone, don't worry about it, it's only a cigar box. Do not glue the thing together, that will make it impossible to do any repairs to it in future.

If it really bugs you, glue some small blocks into the corners of the lower part of the box and make them tall enough to extend into the top, then you can put some small screws thru the top part of the side and into the block whilst clamping the whole thing as tight as you can get.

Thanks John. I just happened to have a little triangle of red oak that fit perfectly into one corner. In fact, the lid fits so tight now that it's the only thing keeping the box together. I'll stick a screw in it just to be thorough. Can't see much of a gap anymore either!

Great idea... I like the silicone glue idea and will add that to the growing pile of great ideas! Thx Wayfinder

Use the thin veneer that comes inside some boxes boxes to build up the gap one strip per side top and bottom. I just super glue them in place then shave them flush then I use the block/ screw method that chickenbone talked about. That way it's wood on wood no cutting to get back inside.
I now make a controll access panel in the back so I do not have to pull strings to do electrical work. After 300 some guitars it just started to make sense to take the time to plan that into the build.

That kind of experience (300+ guitars) is no joke. Thanks, Shawn. I never would've thought you could learn so much from building cbgs. Love it.

Thanks Richard I have been building for over 9 years now and still learning new tricks and tips.

Hi, glue  sandpaper to a flat surface, eg old sheet of glass, and run the two, or just the offending opening edge over this. You could end up chasing you tail with planning. I do this on all my boxes before gluing the tops and backs on.

Cheers Taff

ok yes! I forgot about using a large flat surface ( I have a big ceramic tile) with sandpaper as a sort of "plane". thx!

That's my way too.

And I glue everything together because I like how it vibrates with the neck.

I just make sure that I can access the electronics one way or another...

Are the hinges inside out?

Sometimes little hinges can be flipped around so there is no gap.

Personally I would have just taken them off and used a chisel/craft knife to deepen the recess that they fit in. Much like you do when you hang a new door.

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