I'll be drilling and taping 6-32 threads into the plastic to fasten this latch.
 

I'm getting ready to machine the plastic lid to size so I'm taking some measurements. This will get me close and then I'll make my final measurement with some six inch calipers.
 

Once I had one end cleaned up, it was time to machine the opposite end to length. I did the same thing here as I did on those longer side wood pieces on the box; left it long, measured how much was overhanging with my calipers and then milled off that amount.
 

Like I said before, gluing can be stressful because you really have one shot at doing it right. It was cold in the garage that day so I took the glue into the house to keep it warm and then brought it out to work with. It spreads much better this way.
 

I used my orbital sander on the outside and bottom of the box, which worked really well. Once I had all the inside and outside sanding finished, I used my router table to put a 3/16" corner round on the top and sides of the box.
 

I deiced to use some spray semi-gloss urethane for this project for two reasons. First, the fine spray of an aerosol can gets applied much more consistent than if I brushed it on. The area I'm talking about is the channel for the lid to slide in. If I had an area that ended up getting a drip or globed on somehow, the lid might work right. And the second reason is, time. I'm running out of time on this project and if I used the oil based semi-gloss polyurethane product from Zarr, it would take days for it to dry. Plus, the oil based product would smell for a month...at least.