As a small disclaimer I haven't made much out of wood before. This will probably become more apparent as the box progresses. Constructive comments are welcome, bare in mind I don't have access to many power tools.
Step 1: Design
The initial design here shows lines I want to have marked into the wood on the light grey areas. I also chose the colours at this point after changing the design a few times.
Step 2: Materials and Tools List
MDF sheet 1220mm*660mm*12mm @£13.51
Cornering wood 2500mm @£6.98
2 hinges @£4.48
100 screws 7.5mm @£4.68 (I later changed my idea to use dowel instead, rendering most of these useless)
25 screws 2.5mm @£3.58 (used to attach the base to the sides. I wanted to use plenty of screws here to ensure the bottom wouldn't fall off when moving)
62 dowel @£? most I already had from a previous project (instructable pending :D)
A padlock I had from this years lockerhouse at download festival. (side note: definitely recommend going if your into rock/heavy metal/other)
A latch for the padlock £2
Paint. originally £2 each for 3 tester pots £6 total. However during painting I realised I needed more of the medium Gray since I did the inside this colour too. I forked out £20 for a big 750ml knowing I could use it on future projects so I didn't add this to the total.
Woodglue which I already had.
Tools required for build*
Screwdrivers (Phillips and flathead)
Paint brush (duh)
Dremel/drill Both could be used here.
Since I already had the tools I didn't include them in the total which came to £41.23 (currently $67.39 at time of writing)
*Please note that while I use my tools with care and attention, you may not. I am not liable for anything you do while following this instructable. Or anything else you do while not following this instructable :) Use care when handling powertools.
Step 3: Measuring
I apologise for the picture quality here, the pencil marks aren't the easiest to photograph.
Step 4: Cutting the MDF
Step 5: Assembly Part 1
Using a 5mm drill for the dowel holes and the dremel drill bit for the screw holes I proceeded to mark and drill all the holes I needed to put these together. This is shown better in the picture notes. Make sure to clamp the wood down to make drilling easier and hold the drill at right angle to the wood.
Step 6: Assembly Part 2
While putting the sides together I used wood filler to fill the cracks between the wood on the small side panels. When dry this was sanded. Unfortunately I didn't take pictures of this. Too engaged in my work :)
Step 7: Assembly Part 3
Mark the middle of the front of the box, place the latch receiver over it and mark the drill holes. Do the same for the lid and place the latch arm over it marking the drill holes.
The screws for both hinges and latch did go all the way through my wood. Using a dremel you will need to sand the screws down on the inside.
Step 8: Additional Unplanned Assembly
1) Measure before buying. I needed 2 pieces of boarder which I didn't have. I used woodfiller and build half a side panel with it. Worked surprisingly well.
2) On the hinge line the boarder needed to be cut, so the box could open. Realise this while cutting and not when gluing. :)
3) The top corners will need filling as the boarder leaves a small 9mm square gap where the top side pieces meets the ascending side pieces. I wish I took a photo to explain this better.
Step 9: Engraving the Sides (Optional)
This step is very repetitive as there is many lines on all sides and top to engrave. The more creative person could make something better here and its a great place to change something to make the box feel like your own. After scoring with the knife I found using a triangular file quicker to use.
Step 10: Sanding and Paint Prep
First sand down whole box with rough sandpaper, then repeat with fine sandpaper. Makes the box ready to paint.
Step 11: Paint
Then mark off the painted sides and paint the rest of the wood. I used dark grey. Again I didn't take too many pictures but there all similar and self explanatory.
Step 12: Finished Product
Im glad to have learnt many things through trial and error here and still have a good finished product.
Thanks for reading. Comments welcome. If you make your own links to them in the comment would be appreciated.
The third picture is the preview of my next instructable.