I made this pallet wood gift box with doweled corners for the Sterling Davis pallet wood challenge on YouTube.
I made the box with mitred corners and I was going to use splines to make the corners stronger but decided to use dowels instead.
I made a YouTube video of the process for my channel BCDesign
What you will need:
- 8mm wood bit
- Mitre saw
- 8mm wood dowels
- Wood glue
- masking tape
- 2 hinges
- 10cm of chain
- 16mm screws
- Clasps to close the box
- danish oil
Step 1: Cut the Pallet to Size
- Find a Pallet that is in good condition
- I used a jigsaw to cut the best boards from the pallet
- I needed enough wood for the 4 sides a top and a bottom
- I used my mitre saw with a stop block to make mitred cuts for the corners.
Step 2: Glue the Box Together
- I dry fitted the parts together before gluing
- I used masking tape to hold the glued mitred corners together
- I then added 2 awesome Piher clamps, make sure not to over tighten the clamps or the corners will slide apart
- I left the box overnight for the glue to dry
Step 3: Drill 8mm Holes for the Corners & Base
- I removed the box from the clamps and sanded the box from 120-320 grit
- I then marked the corners and base where I wanted to put the dowels
- Make sure you pick the appropriate size drill bit and dowels for the thickness of the wood you use.
- Be careful when drilling the corners that you don't drill through to the inside of the box.
- I used a scrap piece of wood clamped to the side of the box that the drill tip would exit to prevent tear out.
- I then put glue in the holes and on the dowels and tapped them into position with a mallet.
- I also drilled holes around the base and added dowels to strengthen the base.
Step 4: Add Hinges & Clasps
- I marked out the position for my hinges
- I then used a chisel to recess the area the hinge would fit in,this makes the lid sit flush when closed
- Screw the hinges into place and make sure the lid closes properly.
- I then marked the position for the clasps on the lid and front of the box and drilled pilot holes to prevent the wood splitting and secured them with screws
Step 5: Cut Chain & Finish With Danish Oil
- I cut 10cm of chain and used a pliers to crimp the first & last links so I could secure it to the box with some screws.
- I then applied 3 layers of danish oil sanding with 320 grit between each coat
- I think the box turned out very nice and like the way the dowels look exposed on the outside of the box.
I made a YouTube video of the process please subscribe and thumbs up if you like it!