Introduction: Pallet Wood & Dowel Corner Gift Box

Picture of Pallet Wood & Dowel Corner Gift Box

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:

  • Drill
  • 8mm wood bit
  • Mitre saw
  • 8mm wood dowels
  • Wood glue
  • masking tape
  • 2 hinges
  • 10cm of chain
  • 16mm screws
  • Clasps to close the box
  • Sandpaper
  • danish oil

Step 1: Cut the Pallet to Size

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of 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!

Link to my channel


KagedCreations (author)2015-11-01

Very nice box and simple too, I'll have to give it a go soon

BCDesign (author)KagedCreations2015-11-02


KanPo Studios (author)2015-09-22

Excellent BCDesign.

I was looking for a box to do an and give out for Christmas with goodies.
Certainly a "favorite" and a must do project.

Thanks for sharing

BCDesign (author)KanPo Studios2015-09-22

Thanks Ray please post a ible or pm me so I can see how your boxes turn out!

KanPo Studios (author)BCDesign2015-09-22

Absolutely , sure will.

ulma doctor (author)2015-09-21

super cool box.

i'll be stealing the idea very soon, thanks for sharing!

diy_bloke (author)2015-09-21

looks great

BCDesign (author)diy_bloke2015-09-21

thank you!

ClenseYourPallet (author)2015-09-20

I really like the design of your box. I have never thought about using dowel for the corners like that. Very cool. Thanks for sharing

thank you,it was fun to make a project out of something that would end up as firewood usually!

About This Instructable




Bio: I like to make fun projects and document it all for my channel BCDesign on YouTube!
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