On Sep 14, 6:43 pm, Robatoy wrote:
On Sep 14, 5:10 pm, Dan wrote:



Folks --

This question came up while looking at some old project plans. They
were done up using cardboard mockups to get ideas of proportion and
space.

Lots of these used the "sliding card" principle of assembly Notches in
components would all slide and click together and you would get a
useful object from a set of flat parts. The sliding method can wait
for some other day......

What I found was that one idea for a basket/Tub involved joining thin
( 1/4 inch plywood ) I had thought that perhaps it would be better
to fetch in some sheet metal and just pop rivet the edges together.
However, a trip today thru the book store ( we have the school for
american craftsman on the RIT campus ) I noticed one of the displays
had been done using a nice grade of plywood butt jointed together and
fastened with staples.

Any know of a good way to join thin plywood pieces?

Luthiers butt-join pieces much thinner than that. As Chris pointed
out, you'd want a good fit.
A single pass with a 1/4" router bit (straight) along a fence, which
cuts through both pieces at the same time (sometimes called a
'dutchman') will give you a perfect fit.

The joint will be stronger than the wood, if done properly.

Traditionally done with a shooting board and plane. Fit is
close enough that the pieces don't even need to be clamped,
just rubbed and pressed together until the horse glue cools.

Joints in guitar bodies are usually reinforced by cleats or braces.