How To Build A Wood Box
The plans, equipment, ability to build a quality wooden box as show
here.
Materials
• 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
