A box full of secrets!
Box inspired in one I saw at a store near home! When I saw it, I was impressed at how easy and functional the box was so I decided to do one myself. This box is an easy DIY that you can give the use you want, it can be to keep stationery, tools, makeup,etc. The only thing you need is basic knowledge of carpentry and access to cutting tools.
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Step 1: Materials & Tools
- Plywood One: A piece of 35cm x 66cm x 9mm.
- Plywood Two: A piece of 30cm x 41cm x 6mm and an extra piece of approximately 10cm x 12cm x 6mm.
- Wood glue
- Table saw
- Miter saw
- Corner clamps
- Tape Measure
- Sandpaper no. 180, 240, 320, 400, 600 and 1200
Step 2: Measure and Cut: Plywood One
The first step is to cut the pieces for our main box from Plywood One, it´ll be cut with the help of the table saw, in 4 pieces of 15 cm high, leaving the remaining piece of 5.1cm, aside. Then, three pieces of 15 cm, should be cut to 30 cm and so, we are left with 3 pieces of 15cm x 30 cm (which will be the base and two long sides) and one of 15cm x 35cm (from where we we will cut the short sides).
Step 3: Cut Short Sides!
The next thing is to cut the short sides, which are pieces of 15cm x 15cm. For this we take our piece of 15cm x 35cm, measure it to 15cm from the long side and cut. Repeat the process and now we have the pieces from our main box!
Step 4: Columns - Tiny Pieces That Make Magic!
Now, we will use the piece that we left aside, the piece that measures 5.1cm x 35cm. The first thing we will do to cut our "columns" is to cut the piece to 4.9 cm high, this will be done on the table saw being very careful as it is a thin piece to manipulate.
Since we have our piece to 4.1cm high, we will cut 4 small pieces of around 1.4cm wide. This cut I made it in the miter saw but you can cut it where you feel more confortable.
Tip: You can cut more than 4 pieces in case you may loose one, more is better than less.
Step 5: Measure and Cut: Plywood Two!
What we are going to do next is cut the pieces for the tray from Plywood Two, it´ll be cut with the help of the table saw, in 3 pieces of 9cm high, leaving the remaining piece of 13.4cm aside. Then, the two pieces of 9cm should be cut to 27.8 cm, now we have the long sides of our tray. The remaining 9cm x 30cm piece, we cut into two pieces of 9 cm x 12.8cm, these will be the sides of our tray.
For the base of the tray we will cut the 13.4cm x 30cm to a piece of 12.8cm x 27.8cm.
Step 6: Tray Divider
From the extra piece of plywood I cut a piece of 9cm x 11.8cm, this piece wil be out tray divider and holder.
Step 7: The 45° Edge - Essential for Assembly*
The next step is to cut a 45 ° angle at the edges of the piece so that we can assemble our box and tray. To achieve this, I recommend that you organize your pieces so that you can see which side you prefer, the orientation of the grain and also make sure you have all your pieces with the correct measurements.
Since you have them organized, continue to mark the edges that you are going to cut:
- For the bottom piece, both the box and tray, all edges are cut.
- For all the pieces that are sides, the two short sides are cut and ONLY ONE long side.
Remember, all angles must meet so you can see a trapeze from the sides.
These cuts I did them with the miter saw, set at a 45°.
*This step can be avoided if you cut you pieces with your table saw blade at a 45° angle, personally I feel it inconvinient becuase sometimes the measurments result inaccurate BUT if you are confortable cutting them from the begining with the angle it's more than okey!
Step 8: Sanding. Soft Wood, Happy Wood.
The next step is sanding, for this box I did it with the Geared Eccentric Sander Rotex RO 125 by Festool but you can do it with sandpaper and you archive the same effect.
For both techniques, you must always start with the lowest number of sandpaper and increase slowly so you really seal the wood, an example of sandpaper sequence: 180, 240, 320, 400, 600 and 1200. Also remember, you have to sand in the grain direction and with even preassure in order to achive an smooth surface.
Step 9: GLUE!
To glue the pieces, place the wood glue on the edges and with the help of a corner grip align the sides so that they join perfectly.
The gluing sequence is first stick a long side with a short side, wait for it to dry perfectly and then glue the other short side. Finally, glue the last long side and the bottom. I do this sequence so that when everytime I glue a piece it becomes easier and easier.
I repeated the same steps for the tray.
Step 10: Columns, the Magic Trick.
To stick the columns, place a very small portion of glue on two sides and the bottom of the column and place it in the corner applying pressure for a few moments so that the glue can be absorbed.
Repeat the same process for the remaining columns being careful that they have the same sides glued to the corners.
Step 11: Final Piece!
For the last piece, measure in the tray from one side to the middle (or where you want to place it) and mark it on both sides, this is so that the division is right.
Put a little glue on the sides and glue it carefully, apply a little pressure for the glue to be absorbed and voilà! you're done assembling!
Step 12: Extra: Finishes.
For this box I opted for a natural finish, only sealing it with a little diluted varnish but if you would like to add colour you can stain the the wood, it looks good too!
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