By: Nathan Smith, Michelle Dominguez, Sunil Ojha, Robert Callaway
NOTE: The dimensions we are using for this project are based upon the size of an Xbox One console and its accessories. Feel free to adjust the dimensions as you see fit for your individual project.
- 1 8’x4’ sheet of ½” Pine Plywood (Cut to specifications at your local hardware store)
- 1 ¼” Finishing Nails
- 1 bottle Titebond II Premium Wood Glue
- 2 Gatehouse Brass Folding Supports (1 Left/1 Right)
- 2 Style Selections Aged Bronze Surface Self-Closing Cabinet Hinges (2-packs)
- 2 Brainerd Dark Bronze 3” Venetian Handles
- 1 quart Valspar Heirloom Red Paint (Satin)
- 1 quart Valspar Golden Castle Paint (Semi-gloss)
- Measuring Tape
- Claw Hammer
- Philips-Head Screwdriver
- Hand Drill with 1/16” Pretrial Bit
- Gator Handheld Sander
- Gator Sandpaper (Grades 50/80/120)
- 2” Paintbrush
- Tarp (For painting)
- 1” Painter’s Tape
- 2 ½” Paintbrush
Step 1: Building the Base
Wood Materials Needed:
A) 1 - 24”x 20” Rectangle (Bottom)
B) 2 – 20” x 16 1/8” Rectangles (Left/Right)
C) 2 – 23” x 16 1/8” Rectangles (Front/Back)
Step 1 – Use your pencil to mark for predrilling around the perimeter of piece A (Bottom).
Mark 5 spots along each 20” side, and 7 along each 24” side.
Step 2 – Using your 1/16” Predrill bit, drill holes halfway through piece A at each mark.
Step 3 – With the help of a partner, stand each piece B upright, and place piece A overtop so that 20” sides align and are flush. Make sure the predrilled side of piece A is facing up.
Step 4 – While your partner lifts piece A, spread a line of wood glue across the 20” top-side of each piece B and lower piece A on top to rejoin them.
NOTE: If wood glue runs down the sides of the material, don’t worry. You can allow the glue to dry and sand if off.
Step 5 – While your partner holds the pieces, hammer one finishing nail into each hole along the 20” side connecting pieces A and both pieces B.
Repeat Steps 3 through 5 with pieces C so that A and C are now connected.
Step 6 – Turn the base on its side so that piece C is facing up. Mark 5 predrill spots along the perimeter of piece C that aligns with pieces B (Left/Right).
Step 7 – Using your 1/16” predrill bit, drill halfway through the plywood at each mark you make on piece C.
Step 8 – While your partner slightly lifts the upright piece C, spread a line of wood glue along each piece B that touches piece C and reconnect.
Step 9 – While your partner holds pieces B and C together, hammer one finishing nail into each hole connecting pieces B and C together.
Flip the base so that the opposite piece C is facing up and repeat Steps 6 through 9.
Step 2: Building the Lid
Wood Materials Needed:
D) 1 - 23 ⅝” x 11 ¼” Rectangle (Top)
NOTE: The 23 ⅝” sides of piece D should be cut at perpendicular 45-degree angles.
E) 2 - 23 ⅝” x 2” Rectangles (Detail Inserts)
F) 2 - 23 ⅝” x 5 ½” Rectangles (Diagonals)
NOTE: Only the 23 ⅝” side connecting to piece(s) G should be cut at 45-degree angles.
G) 2 - 23 ⅝” x 3” Rectangles (Front/Back)
H) 2 - 20” x 8” Pentagons (Left/Right Sides)
NOTE: The pentagon is cut at a 45-degree angle from 3” up either 8” side.
Step 1 - Use your pencil to mark the perimeter of pieces H for pre drilling. Mark 2 along the 3” sides, 5 along the diagonal sides, and 7 about ½” down from the 11” top side.
Step 2 - Use your 1/16” predrill bit to drill halfway through pieces H at each mark.
Step 3 - Spread wood glue along one side of piece G and align it to the 3” side of piece H.
Step 4 - While your partner holds pieces G and H together, hammer one finishing nail into each predrilled hole.
Repeat Steps 3 and 4 until all pieces G and H are connected.
Step 5 - Use your pencil to mark each piece E for predrilling across just one 23 ⅝” side. Mark 7 times.
Step 6 - Use your 1/16” predrill bit to drill halfway through the marks on each piece E.
Step 7 - Spread wood glue along the flat 23 ⅝” side of piece F and align it to the predrilled side of piece E.
Step 8 - While your partner holds pieces E and F together, hammer one finishing nail into each predrilled hole.
Repeat Steps 7 and 8 for the other sets of E and F.
Step 9 - Spread wood glue along the angled side and each end of piece EF and align to the diagonal end of piece H.
Step 10 - While your partner holds the pieces together, hammer one finishing nail into each predrilled hole.
Repeat Steps 9 and 10 for the other piece EF.
Step 11 - Spread wood glue along the entire perimeter of piece D and lay it to align with the predrilled holes is pieces H.
NOTE: This piece should lay flat across the top of pieces EF.
Step 12 - While your partner holds piece D down, hammer one nail into each predrilled hole in pieces H.
Step 13 - Wait at least 30 minutes for the wood glue to set on both the base and lid.
Step 3: Sanding and Base Painting
Step 1 - Using your Handheld Sander with Grade 50 or 80 sandpaper attached, sand any rough spots, spilled glue, and round off edges of the base so that desired smoothness is achieved.
Step 2 - Use a clean 2” brush to wipe away any excess sawdust off of the base and the lid.
Step 3 - Lay down your tarp on the ground and place the lid and base down separately to keep your floor clean from paint and painting area free of sawdust.
Step 4 - Open 1 Quart of your Heirloom Red paint and stir until paint is smooth. Use your 2 ½” brush to paint the base and lid inside and out.
CAUTION: Wear clothing you don’t mind getting paint on and gloves to keep your hands clean.
Step 5 - Prior to moving on to the next steps, allow the paint to dry for at least 2 hours.
Step 4: Adding the Details
Wood Materials Needed:
I) 3 - Triangles (Left over from when you cut the pentagons for the lid)
J) 1 - 3” x 3” Square
K) 2 - 2 ½” x 11 ¼” Rectangles
L) 1 - 3” x 11 ¼” Rectangle
Step 1 - Use your Handheld Sander with grade 50 sandpaper to smooth the surface and round the edges of each piece.
Step 2 - Lay out your pieces on your tarp.
Step 3 - Open the Golden Castle paint and stir until smooth.
Step 4 - Use a clean brush to paint two coats on each piece. Set aside to dry.
Step 5 - Align each piece K on top of the lid on both the left and right sides flush with the ½” raised ends of pieces H (pentagons).
Step 6 - Hammer two finishing nails (one on each end) into each piece K to attach them to the lid.
NOTE: There is no need to predrill for these pieces as they are decoration and do not need to have structural integrity.
Step 7 - Use your measuring tape and pencil to mark a line down the vertical center of the lid.
Step 8 - Align piece L with the center mark, and hammer two finishing nails into each end to attach it to the lid.
Step 9 - Use your measuring tape and pencil to mark a line down both the vertical and horizontal centers of the front of the chest.
Step 10 - Align piece J at the top of vertical center leaving a 1” overlap from the edge of the front. Hammer two finishing nails into piece J to attach it to the front of the chest base.
Step 11 - Align one triangle piece I 2” below piece J along vertical center. Hammer one finishing nail in the center to attach it.
Step 12 - Line up one of each remaining piece I at the base corners of the first piece and attach each with one finishing nail.
Step 13 - Using the template above as a reference, and following the detail pieces you have attached, tape the outline for your gold trim on each side of the chest.
Step 14 - Paint inside the taped outlines. Allow to dry.
Step 15 - Once the paint is completely dry, remove the painter’s tape.
Step 5: Connecting the Lid to the Base
Step 1 - Use your measuring tape to find 3” in along the back of your lid from the left and the right and mark each with a pencil.
Step 2 - Line your cabinet hinges up to the 3” mark and use your pencil to mark each hole in the hinge for predrilling.
Step 3 - Move the hinge away and use your 1/16” predrill bit to make a hole about ¼” into the lid at each mark.
Step 4 - Line each cabinet hinge up with the predrilled holes and use your Philips Head Screwdriver to attach the hinge to the lid.
Step 5 - Place the lid on top of the base and align the front and back of the lid flush with the front and back of the base.
Step 6 - Use your 1/16” predrill bit to make ¼” deep holes into the base through each hole of the two hinges.
Step 7 - Use your Philips Head Screwdriver to attach the hinges to the base.
WARNING: For the next process, you will need to slide the chest into a position where you can prop the lid open and safely work inside.
Step 8 - Take the two Gatehouse Brass Folding Supports out of their packaging and place them on their corresponding left and right sides INSIDE the chest.
Step 9 - Attach the Folding Supports following the packaged instructions for both the left and the right insides.
WARNING: It is very important that you attach the folding supports. The weight of the lid following these specifications is too much for the hinges to support on their own.