> But, i do want to replicate the yankee 100 box as much as I can and
> will have a go at it with hand tools.

I understand and share this idea for the box.  I might even get a little
crazier and search out chestnut stock for it (chestnut was the usual 
wood
of choice in these boxes).

My only suggestion would be to fit a stop onto the saw (dovetail saw?)
so that you don't have to think about when the cut is precisely at the
right depth.

There will be pictures of the finished box, right?  Maybe photos of the
process, too?

Mike in Sacto