This is a chest I built for a friends son, after I installed this, his brother wanted the same one. So I made another. The boys have a lot of stuffed animals that where kept in cardboard boxes, but after a week or so the box would break.
With this instructable I would like to share my view of this project and hopefully inspire you to make one yourself. I will try and cover all the information you need, but if I miss something or you just want to know something, let me know.
The chest is open on top, and has sliding doors at one small side (not installed, the buyers have their own panels at home).
Step 1: Cutting the Wood
When making this box I had a simple drawing, but I needed a detailed version so I could work with ease.
So as a pressent for you, I made a automatic excel-file ;-)
Left side in mm and on the right inch, (for inch I copied the mm and devided bij 25.4)
Fill in the red fields and your own box will be calculated.
Even with the excel-file I made a mistake on the first box, while sawing the grooves. (The top 4 beams/bars have 2 grooves, because I thought they would have a panel on top. Silly me ;-) )
!!! Not in the excel-file:
The middle beams need to have a groove (about halfway through) , to place the panel that is located inside the box.
Step 2: Montage
Before placing the panels inside the beams, chamfer / bevel the sides (with sandpaper or a handplane).
This step will make the panels "slide" in the grooves easier.
Every beam is hold in place, with a single screw (7 cm or 2 2/3 inch long). They won't rotate because the panels are holding them steady.
Every screw is predrilled and countersinked (I think countersinked is the word I'm looking for (eng not my first language) head of screw is level with the wood surface.)
When placing the bottom and middle panel, the corners of the panels need to be removed. See drawing.
Another solution is cutting the pieces out of the legs, but I think removing the corners is faster.
Step 3: Sliding Doors
Pictures: box is upside down !!!
When making the grooves, add the second groove after all other grooves are made. Doing this will make that all groves are aligned.
The bottom and middle beam/bar have double grooves so sliding panels can be placed.
The grooves in the middle beam (top of the doors) are deeper, so the sliding panels can be put in and take out without disassembling the box.
Step 4: Finishing
This box will be standing in the childs bedroom, so for the kids safety I wanted to keep the splintering at a minimum.
I rounded the edges with a compact router.
1/4" / 6mm round over bit, with a botom bearing
Hereafter electric/machine sanding the beams/bars to get a smooth surface.
Step 5: Thanks for Viewing
Thanks for your interest in this project.
If you have any questions, feel free to ask.
Over all I'm happy with the way the chest turned out and I hope it inspires you to build one.