Bill Epstein Messages: 1088 Registered: May 2009 Location: Smoky Mts. USA
Illuminati (2nd Degree)
As you've discovered, if you cut the rabbet after gluing up the box you're left with the rounded corners. Just use 1/2" or bigger chisel to cut the square. Use the extra width of the flat edge to index against the already cut side of the rabbet. Alternate your cuts from one side of the corner to the other so as not to have a split.
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