To install lift tabs in box lids, I first rout a groove on the front edge of the lid with a 1/8 in router bit about 3/16 in. deep. I then saw stock to a thickness of 1/8 in. and about 3/4 in. wide which I then cut to the length of the grooves cut in the lids. I work in fitting one tab to a lid at a time due to possible variations.
I use a piece of self-adhesive sand paper on a flat board to round the corners to fit the grooves. Can't fit a square peg in a round hole except by making it too small to fit.
What you see in the photo are lids with the lift tabs fitted but not yet shaped.
Make, fix and create...
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