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TechShop makes things happen - I've got plenty of projects that I build there.

Check them out!   www.techshop.ws

I have a bookshelf that's 9.5" deep, and I needed some  hanging file boxes that would fit next to my books.

Most hanging file boxes are much bigger and deeper, so I designed my own...

The included files were created in Corel Draw 5.

You may want to add graphics or names or numbers to your fileboxes.

Step 1: Gather the Materials...

I like to use MDF for many of my projects.  I usually get 1/.8" and 1/4" MDF panels at Home Depot, since their quality is very consistent, and there are lots of Home Depots! They sell each type in 24"x48" panels near me.

Since I use a 60-watt Epilog Laser that has a 24"x18" bed, I prepare my MDF by cutting the panels to 24"x18".

Materials for one Hanging File Folder Box:

2  of  24"x18" panels of 1/4" MDF

1  of  24"x18" panel of 1/8" MDF

White or Woodworker's Glue

Step 2: Cut the 1/8"- Thick Bottom...

The photo shows the bottom in the middle of all the pieces.

Since the Bottom will not support any weight, I made it out of 1/8" MDF.  The joints at the bottom of the front, back, and sides are designed for 1/8" MDF.

Once I loaded the FileBox Bottom .cdr file, I made sure the laser driver was set to 24"x18" to cut all the vectors.

I set the 60-watt laser to 18 percent speed and 90 percent power when burning the bottom piece.

Step 3: Cut the Front and Back From 1/4" MDF

The photo shows the front and back on above and below the bottom here.

The Front and Back can be modified as needed with graphics or text. 

Once I loaded the FileBox FrontandRear .cdr file, I made sure the laser driver was set to 24"x18" to cut all the vectors.

I set the 60-watt laser to 9 percent speed and 90 percent power when burning the front and back.

Step 4: Cut the Sides From 1/4" MDF

Here's an action shot - the sides are being cut from a single panel.

Load the FileBox Sides file and use the same power and speed settings as were used in cutting the Front and Back.

Step 5: Assemble the Parts...


DRY FIT FIRST.  It just makes the whole process easier if you know how they'll fit before getting things glued.

I like to use Elmer's White Glue, since many of my projects are for kids.  This project would be fine with any type of wood glue.

Be sure to put glue on all surfaces that meet other pieces.

Assemble is straightforward - you may like having an extra set of hands to help hold the pieces as you assemble.

I often use blue painter's tape to hold these together until the glue dries.  Woodworking clamps will work also.

I made it at TechShop San Jose!  http://techshop.ws

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