Introduction: How to Make a Wooden Box Joint Box
In this video I'm going to show you how to make a wooden box with box joints. However, there is a twist. Most boxes use hinges or a sliding lid, this box opens in a unique way you won't usually see. But you’re going to need to watch the video to see what that is!
I’ll show you how to cut the frame, cut box joints, use wood glue to glue the frame together, build the top and bottom assembly and finally, apply finish.
Most of the work was done on my DeWalt table saw with the help of my box joint jig and my cross cut sled. Links below.
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Table saw w/ box joint jig and cross cut sled (videos to build them on my channel)
Drill and drill bits
Dado blade set
1x6 pine board
Step 1: Cut Frame to Size
Decide how big you want to make your box and cut the1x6 pieces to size.
Step 2: Cut Box Joints
Install your dado set and get out your box joint jig. Now cut all your box joints in all four frame pieces.
Step 3: Dry Fit Frame
Assemble the frame with no glue just to make sure all the joints are cut properly.
Step 4: Make Corner Supports
Now reinstall your standard table saw blade and cut 4 corner pieces to keep the box square but also to stop the lid mechanism when fully opened and closed.
Step 5: Assemble Frame
Apply glue to the box joint ends making sure to get glue on all edges of the joints. Now assemble the box together. Make sure everything is fully seated and square. Now clamp in the corner pieces. Use a scrap piece of the lid material to space the supports from the top. The supports should hold the lid flush with the top of the frame.
Step 6: Build Top/bottom Assembly
Cut top and bottom pieces that fit nicely but but still slide freely. Now cut two pieces for either side of the box that connect the top on bottom. They will need to be narrow enough to fit in between the corner pieces install earlier. Test fit all pieces.
Now drill a finger hole in the top piece. I used a 1" forstner bit. Now glue and brad nail the components so when they are assembled, the top/bottom assembly can slide up and down to open the box. The top and bottom should be flush with the frame and the assembly should stop in the opened and closed position on the corner pieces.
Sink all brad nails just below the surface.
Step 7: Apply Finishing
Fill all small holes with wood filler. Then sand with 80, 120 and 220 grit sand paper until its all perfectly smooth. Finally, wax the entire box and the mechanism with paste wax. Test for smooth operation.
If you like this concept but want a different size box, you can scale it up and down.
Enjoy your cool little box for storing small things.
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