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Step 8Starting the box
The main purpose of the box is to shelve and protect the chessboard, but it also helps cover all the wires and even out the base. The box I made for this project was produced entirely out of scrap wood. If using what was lying around is good enough for me than it is good enough for you, so I will not be specific with the sizes and focus mainly on the building technique.
Prepping the wood - Four even pieces of wood, each slightly longer in length than a side of the copper plate, are needed to form the sides of the box. Measure the combined thickness of the copper / wood plate, and cut a shelf of that thickness into the wood. The shelf should be as high up the wood as possible, but have a thick enough overhang that it will not snap or break when the chess board is being pushed into it. The reason for the overhang is to hide the two wires soldered to the board. Cut the ends of the four pieces of wood at 45 degree angles. On two of the pieces of wood, shave a bit of the underside of the overhang and cut a small grove into the shelf, so the soldered wires have room to fit in when the box is closed.
Putting the pieces together - Lay out a strip of painters tape sticky side up. The length of the tape should be a few inches longer than the combined length of the wood sides. Lay the four wood sides down on the tape, making sure to line up the orientation of the two notched sides with the two wired corners of the board. Put the board into one of the sides, and put wood glue on each of the 45 degree angle cuts. Fold the side pieces around the board, and use the excess tape to hold them in place. Square all the corners (using a rubber mallet if need be), and place clamps across all four sides. After the glue has set remove the clamps and tape.
Prepping the wood - Four even pieces of wood, each slightly longer in length than a side of the copper plate, are needed to form the sides of the box. Measure the combined thickness of the copper / wood plate, and cut a shelf of that thickness into the wood. The shelf should be as high up the wood as possible, but have a thick enough overhang that it will not snap or break when the chess board is being pushed into it. The reason for the overhang is to hide the two wires soldered to the board. Cut the ends of the four pieces of wood at 45 degree angles. On two of the pieces of wood, shave a bit of the underside of the overhang and cut a small grove into the shelf, so the soldered wires have room to fit in when the box is closed.
Putting the pieces together - Lay out a strip of painters tape sticky side up. The length of the tape should be a few inches longer than the combined length of the wood sides. Lay the four wood sides down on the tape, making sure to line up the orientation of the two notched sides with the two wired corners of the board. Put the board into one of the sides, and put wood glue on each of the 45 degree angle cuts. Fold the side pieces around the board, and use the excess tape to hold them in place. Square all the corners (using a rubber mallet if need be), and place clamps across all four sides. After the glue has set remove the clamps and tape.
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