Step 1: What You Need!
Step 2: Your First Cuts!
Using a sharp craft knife, cut the following strips of foam core boards and label lightly on one side with pencil (A,B,C,D) TIP: Using a sharp knife is essential both in terms of safety and also achieving clean cuts. A dull blade will result in ripped foam, spoiling the end result.
A = 20" x 4.5"
B = 20" x 2"
C = 12" x 4"
D = 12" x 3 5/8"
Step 3: Turning Paper Back Into Wood...
Coat 1 (Background color 1) = A wash (use lots of water mixed with the paint) with bright yellow. Allow to dry for 10 mins.
Coat 2 (Background color 2) = A wash with Brown/ Ocre. While still wet, rub with kitchen towel/ tissue in a continuous line along the centre of the entire length of each strip, giving a lighter appearance in the center of the Ã¢â¬ï¿½woodÃ¢â¬ï¿½. Allow to dry for 10 mins
Coat 3 (The Grain 1) = Brown Ocre. Dab the brush in undiluted Ocre paint and then dab on tissue paper to remove excess paint. Run the brush along the entire length of the board repeat until all of the wood is covered. Allow to dry for 10 mins. TIP: Always brush the entire length of the board Ã¢â¬â€ tree grain does not stop!
Coat 4 (The Grain 2) = Burnt Umber. As with the 3rd coat, repeat with a darker brown paint. Again allow to dry for 10 mins
Coat 5 Allow to dry before coating generuously with all purpose glue. Allow to dry thoroughly before continuing.
Step 4: Cutting Up the Planks
A = 6",4",6",4"
B = 5 1/2", 3 1/2", 5 1/2", 3 1/2"
C = 6", 6"
D = 5 1/2", 5 1/2" (Save the remainder for step 13)
Note:From this point on the pieces will be described by their letter and length. i.e. The 6" x 4.5" section from length A will be denoted A6"
Step 5: Cutting Notches in the Foam Core.
Take both A6" section and place painted side down on a craft cutting mat. Carefully cut a 5/16" strip from both 4" ends, only cutting through the non painted backing and the foam itself (do not cut through the painted part of the board). Next cut down through the foam itself. This should leave you with 2 notches in each bored as shown in the image below.
Repeat for both B51/2" sections, this time cutting from the 2" sides.
Repeat for both C6" sections, this time cut from all four sides.
Repeat for one of the D51/2 sections, again cutting from all four sides
Step 6: More Cuts to Make the Lid
Step 7: Painting the Hidden Compartment Sections
Step 8: Felting the Box
Repeat step 12 on both D5 1/2 sections (ensure you felt the notched side of the one notched D5 1/2" section) and the non-painted side of all four 1.5" width A sections.
Once dry cut away the excess felt as neatly as possible with a pair of sharp scissors. TIP: Don't try and cut felt with a knife, it will dull your blade very quickly and will tear the felt rather than cut through it.
Step 9: Glue the Box Together
Glue the four B sections together to make up the sides of the inner box. Glue the notched D5 1/2" section on the bottom with the felt-side inside.
Hold everything in place with rubber bands while the glue dries.
Step 10: Secret Panel Supports
Step 11: Finishing Up
To finish the box you can paint up any exposed foam core (eg the supports from step 13). Using a neutral colored felt tip pen/ paint, carefully color any exposed white edges. Close the box and spray with a gloss finish of your choice.
See the intro for finished pics.
Enjoy your box!