This storage box has a large wood storage area and a top area for those little things such as kindling, fire lighters and paper. The parts are cut from one sheet of 2400 X 1200 X 18mm ( 8 feet X 4 feet X 3/4 inch) ply. Finish to match your room using stain and a suitable top coat such as marine varnish or acrylic paint. Top and sides can be painted using folk art techniques. Time to make and finish is about two days.
Step 1: Cutting Out Pieces
Download cutting diagram. There are three 900mm X 100mm (3 feet X 4inch) pieces. One is attached to the edge of the "cupboard base" before fixing the base into the box.
1. Cut all pieces out as shown on the cutting diagram.
2. Save two of the 900mm X 100mm to cut in to complete the top cupboard.
3. Router the edges for a rounded or fluted finish if wanted.
4. Sand all parts with 120 and 240 grit paper.
Step 2: Screwing and Gluing
1. Lay back down on a flat surface and attach sides, ensuring that back edge of the sides is level with the back. I used two pieces of 4 X 3 to hold the sides at 90 degrees to the back.
2. Lay in base inside the back and sides. This will square up the project.
3. Fix by gluing and nailing or screwing. I used pocket hole joining to hide fixings but fine nails or screws and plugs will do the same thing. Once the base, back and sides are fixed, allow 20 minutes for glue to set.
4. Fasten the 900mm X 100mm front to the cupboard base. Fix using glue and same method as used previously.
5. Measure up from inside of base 600 mm and draw a line around as a guide to fix the cupboard base.
6. Fix cupboard base using glue and pocket hole joining or fine nails unless you want the screws to be a feature.
7. See picture. measure and cut 900mm down to fit inside back of cupboard. Measuring this after fitting will ensure that it is the right height to fit the lid. Glue and nail from behind and below
8. Cut two side inserts and fit tightly then nail from below. This will complete the cupboard assembly.
1. Easiest way to construct the lid is to join both parts together during the cutting and hinge fitting. This ensures that both parts are flush at the front and sit well.
2. Join both parts of the lid using a piece of scrap. Ensure that this does not stop lid from sitting flush on top of cupboard.
3. Cut 40mm strip off the back of the lid.and join strip back on lid using a 900 mm piano hinge or similar.
4. Sit lid on cupboard and decide on overhang. I used 30mm (1 1/2") but more or less is fine depending on your existing furnishings. You might like a flush finish and add handles on the front or top. 30mm gives the same recess as the bottom of the box.
5. Glue back strip to back of cupboard lining and back nail.
6. Allow glue to dry for about 20 minutes then remove joining strip.
7. Finish to match your furnishings and add a strip of felt under the lids to create a soft close.
Install the box and fill. Good luck with your project.