To get an overview how I made this, watch the Video.
Step 1: Cutting
My 2x4 was an irregular 2x4 because it was 2"x 4"
But if you use a bandsaw instead of a table saw then a normal 2x4 is big enough!
My Tardis has only two walls, so I cut the 2x4 in two pieces, one for each wall.
I divided it in 10 pieces and cut 8 on the table saw
Step 2: Dimensions
The TARDIS has two walls and each wall is divided in a upper frame and a lower frame.
The dimension of the TARDIS depends from the 2x4 and the thickness of your saw blade.
Thickness of one stripe = (width / 10) - the thickness of your saw blade
Cut 8 stripes, the last piece is one saw blade thicker
Tilt these piece 90° and cut it in 5 stripes
Here the last piece is also one saw blade thicker. Use this for the bottom.
The height of the lower frame = (the length of the 2x4 - one saw blade )/2
The width is determined by the length of the crossbars (one stripe=6 crossbars)
The height of the upper frame is the half of the lower frame + the top
In the upper Frame the windows are equal with the fields in the lower frame
Step 3: Making Half-lap Joints
All the crosspieces are joint with half-lap joints, made on the table saw
Step 4: Gluing the Frame
I put all together and glued it with wood glue.
Step 5: The Sign
For the sign I used a 4mm plywood and painted it black.
The letters are printed on paper. I cut them out and glued them on the board.
The frame was built with finger-joints
Later I glued it on the upper frame.
Step 6: Windows and Top
Windows and top were made with half-lap joints and glued on the upper frame
Step 7: Lock the Two Frames Together
To lock upper frame und lower frame together I used some extra pieces of hardwood.
The upper frame gets 3 "fingers" and the lower frame 3 pockets.
Step 8: Painting and Cover
For the windows I used white cotton and for the walls blue cotton.
Step 9: The Hinges
Instead of hinges I used wooden blocks with two holes and stitched them together with rubber band
Step 10: Fine Tuning
I closed the gap in the corner with an extra piece and I made a lamp wich sits on a diagonal bar.
If you like it, please vote for it in the 2x4 contest. Thank you.