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I like the idea of a box with secret locks, so I thought I would try a different type of lock on this one.

Step 1: I Used

This box is pretty big. I used approx 2'x4' of 3/8" plywood, 38" of 1x2 pine, 35" of 1x2 pine ripped to make 1/2x2, 2" of 1" dowel, 8" of 3/8" dowel, 1" of 1/4" dowel

Step 2: Cut Parts, Drill Lock Holes and Make Locks

I cut: main box- 4 pieces of plywood 16"x8" for sides, 2 pieces 7 5/8"x 7 1/8" for the ends.Large drawer- 1- 15"x 7 1/8" for the long side that locks, 1- 10"x 7 3/4" for the short side, 1 4"x 7 1/4" for the top slider, 1- 10"x 7 3/4" for the bottom and 1- 7 3/8"x 7 3/8" for the back. For the short drawer- 2- 7 3/8"x 7 5/8" for the sides of the small drawer, 1- 4"x 7 5/8" for the back of the drawer and 1- 3 5/8"x 7" for the bottom of the drawer. The strapping around the box was cut to 10" for the top and 8 3/4" for the sides. The 1/2"x 2" for the trim on the ends were cut to 8" and 8 3/4", with 45° ends to make a frame. The 1" dowels are cut to ~3/8" thick with 3/8" holes in the centers for the 3/8" dowels and 2 of the 3/8" dowels cut to 2" long with a notch in the end to hold 1/4" dowel cut 1/2" long. For the small drawer, I cut ~5" off the side of the main box to make the front. I lined up the long side of the main box, the long side of the large drawer and the back of the small drawer, clamped and drilled a 3/8" hole ~2 1/2" from the side for 1 of the turn-locks, another hole 2 1/2" from the other end for a pin lock.

Step 3: Clamp and Glue

I clamped and glued the main box together with the top and bottom inside the sides and glued the back end in (small drawer end of main box) Another option would be to glue the other end shut and have the large drawer slide out past the small drawer hole. Kinda wish I had thought of that earlier now. I also glued the drawers together making sure first that everything would fit and slide well. The back of the small drawer is 3/8" narrower than the drawer to hold a 3"x 3/8" sq piece that is glued on the end of the long side of the large drawer

Step 4: Cut Slots for the Locks

So I have 2 pin lock holes drilled in the top of the main box 2 1/2" from each end and centred. One drops in to the small drawer and the other drops in to the top slider of the large drawer. One pin lock on the side that goes in through the long side of the large drawer and a turn-lock that goes through the side of the main box, long side of the large drawer and back of the small drawer. There is also a turn-lock that goes through the end of the box into the side of the small drawer. The remaining 3 knobs are for handles for the 2 drawers and another glued to the side of the main box to keep everything even. To cut the slots for the turn-locks I put all the pin locks in to hold things together and used a plunge-cut router bit for the slots, just trimming a bit at a time until the turn-locks just fit

Step 5: Finishing Touches

Once I had all the locking pins working properly, I put the whole thing together and cut and glued the strapping around the box as well as the frames on the ends. Be sure to glue the frame to the end of the long drawer, not the main box so it will still slide Pic 1 shows how the 2 drawers will fit together before I completed the large drawer. Pic 2 show the different types of locks I used and pic 3 gives a better idea of how it all goes together

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