I wanted to make a classic wooden trunk to hold some analog camera equipment while traveling. This is basically a large box utilizing box joints for construction, some leather straps for extra security, some nice locking clasps and a leather handle. Obviously the size can be adjusted to make it fit whatever you're looking to store. Make sure to check out the video for the whole build process!
Step 1: Size
To determine the size of the box, I laid everything out on a table that I wanted to keep inside and then I measured accordingly. For materials I decided to use 1/2 inch white oak for the sides and 1/8 inch rosewood for the top and the bottom panels.
Step 2: Construction
I cut the wood up to size, and then I used my box joint jig for the table saw to cut box joints (plans available here if you'd like to build the same jig: http://www.darbinorvar.com/misc/box-joint-jig-plan ) You could also hand cut box joints, or use a router for example.
Step 3: Glue Up
Once the joints were cut I glued them together with clamps, taking extra care to ensure the corners were square.
Step 4: Top & Bottom Panels
To create the top and bottom panels, I glued up some 1/8 inch rosewood, and added some wooden straps for extra glue surface.
Step 5: Glue-Up
Once the panels were dried, I glued them to the oak case using many clamps to ensure a good connection.
Step 6: Tablesaw Cut
At this point we had a closed box, and it was time to cut it open on the table saw! To do this, I first cut three sides, then attached a small spacer with tape inside the cut, and proceeded to make the final cut.
Step 7: Routing
To create a rounded edge on all the corners, I used a handheld router.
Step 8: Fabric
Since the top and bottom panels are so thin, I was concerned that perhaps they could crack if the case was accidentally dropped. So to ensure more strength, I decided to glue some canvas to the panels using some water based contact cement.
Step 9: Locks
For locks I decided to use vintage style combination locks. To attach these you first have to cut some mortises which was done using the handheld router.
Step 10: Hinges
I added some nice, matching brass hinges in the back.
Step 11: Sanding
Finally, sanding to make sure everything was nice and smooth.
Step 12: Leather Straps
To provide extra security (and looks!) I cut some leather into straps, added snaps to one side, and then glued the straps all around the box using contact cement. At that point I added the second part of the snaps to be able to close the straps.
Step 13: Handle
For a handle, I made a thick leather handle using the same material as the straps that I sewed together. Then I drilled a hole in the sides of the handle as well as the box and secured it with some brass bolts and nuts.
Step 14: Organization
To create a snug fit for the equipment inside the box, I used Kaizen foam which is easy to carve out of to make each thing perfectly.
Step 15: Finish
For a finish - shellac first, and then linseed oil beeswax polish!
Step 16: Conclusion - Watch the Video
For a much better perspective of all the steps, and to see the final product, make sure to check out the video!