How To Build A Wood Box

Rod has the plans, equipment, ability to build a quality wooden box as show here. - Helping You Make Wood Work

  • Two Pieces, 1" rough Oak or other hardwood: 8" x 96"
  • One Piece, 1/4" Plywood: 12" x 20"
  • Pair of Hinges
  • One Hasp
  • Friction Lid Support
  • Eight Wood Screws: 1 5/8"
  • Eight Felt Pads
  • Sandpaper
  • Wood Filler
  • Satin Finish Polyurethane

Step 1: Make the Board Material - Select the two, one inch hardwood boards

  • Rip the rough edge of each board
  • Adjust the fence and rip the other rough edge of each
  • Both boards have two straight edges; rip each board in half
  • Glue and clamp the four boards together, alternating the woodgrain
  • After the glue has dried overnight, run it through the planer to 3/4"

Step 2: Cut the Panels to Size - Select the 15" (Approximate width) x 96"

  • Rip the board to 12" (remove material from each edge)
  • Crosscut three pieces @ 20"
  • Crosscut two pieces @ 12"
  • Mark with a pencil, all the edges: "Front, Back, Right, Left, Interior, Exterior"
  • Select the 1/4" plywood for the bottom panel and cut it as shown above

Step 3: Cut the Box Joints - Select the four, 3/4" boards: Front, Back, and two Sides

  • Cut the 3/4" Box Joints with a push router and jig as shown above
  • Using your table saw, make the 1/4" wide (two passes with a standard blade) x 3/8" deep dado cut to receive the bottom panel on the interior, 1 5/8" from the bottom edge of each of the four panels: Front, Back, Left Side, Right Side
  • Dry-fit the box

Step 4: Cutout the legs - Select the Front, Back, and two Sides

  • Using a Bandsaw, cutout the legs per the dimensions as shown above
  • Sand all edges and surfaces (especially the interior) of the box with the exception of the box joints - DO NOT SAND THE BOX JOINTS

Step 5: Glue, Assemble, and Sand - Select all the pieces: Front, Back, Two sides, and the Bottom Panel

  • Glue and clamp all sides with the bottom panel in place (avoid all glue spills on the interior of the box)
  • Ensure the box corners are tight and square
  • Select eight screws @ 1 5/8" and pre-drill and screw them into each corner Top and Bottom, below the surface
  • Allow to dry over night
  • Glue and clamp the Top Panel into place (no screws) and allow to dry over night
  • Using a Belt Sander, sand all the rough box joints and the Top Panel so they are all smooth to the touch; no rough edges
  • Use a Finishing Sander to complete the sanding

Step 6: Cut the Top Lid, Finish, and apply Hardware - Select the completed box

  • Set the fence of the table saw so that it cuts at the first joint (1 1/4" down from the top edge), as shown above; cut in the following order: 1.Front Panel 2.Back Panel 3.Insert a spacer the thickness of the sawblade in both grooves and clamp them 4.Cut Right Side 5.Cut Left Side
  • Complete all sanding and apply a minimum of three coats of polyurethane
  • Apply the hinges, Hasp, Lid Support, Felt Tabs

Copyright 2013 - Wayne Murray

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