Introduction: Box

About: I'm an Industrial Designer. I've always had an interest in building things. I believe it's important for designers to be in touch with their materials and how to construct and manufacture the products they c...

This is a sewing case I did for a friend of mine. It's made almost exclusively in wood (mahogany and pine), except for the hinges and locks. The design works a lot with basic contrasts, dark/light, open/closed, outside/inside, soft/hard etc. and most of it was thought out as it was being built. The primary tools used for doing this were a table saw and a power router.
Sorry for the crappy picture quality



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    10 Discussions

    I really liked this. Can I have a cut list and assemble directions? (I have to build a box for one of my classes and I would love if I could use your design).

    4 replies

    I've done a quick sketch of the way I did the outer box. These steps are for one of the four sides, but the procedure is the same for each one. You'll need a power router and a table-saw for most of the work. Steps 1-5 are done using a power router with first a straight drill-bit and a rounded one for the outer edge. The radius is exaggerated a bit on the drawing, but find whichever one suits you. (this could also be done using a drill, a jig saw, a table saw and a file + sandpaper, but it'll be easier to do with a power router and the result will probably look a lot better) Step 6 is done using a table-saw set to a 45 degree angle. these Cuts need to be very precise, and the angle has to be 45 or preferably just a little less to avoid gaps showing at the assembling-line. Step 7/8 I did using a jig-saw and a file, but the rounded corners should not be cut/filed away until the box is assembled as it will be easier to make a proper rounded corner, so maybe just save this step for last. After this you should have a piece looking something like step 9. This piece is then cut where you want the box to open. It needs to be pretty high if you intend to open with a hinge as the top will otherwise not be able to open. By the way, if you want a perfectly square/cubic box, you should make the pieces about 5mm/0.2 inches longer on the side you intend to cut to compensate for the wood the saw removes. When you have made your four pieces like this, simply glue them together and use sandpaper to remove any irregularities. Finally make the box/boxes for the inside. Those should be somewhat self explanatory. I've avoided adding measurements as I can't remember them, and it will allow you to scale the principles to whatever size box you want. You should be aware however on step 1-2 to maintain the same thickness on the bottom that you have on the sides. If you have any questions, ask away.


    Oh, and remember to place tape on the wood when doing the cut in step 10-11 as the wood will otherwise chip. I forgot to do this and it bothers me to this day :)

    Thank you :) I've added a sketch of how I did the outer box in a comment above if you want to try something similar. I've also added the sketch to the slideshow for a higher res version, but it seems to take a couple days before it pops up.