This instructable is on making a laptop accessory box. I've been facing the issues of space in my laptop bag and the pouch which I presently use for keeping my laptop accessories is not only very bulky but also takes up a lot of horizontal space rather than vertical, hence making it difficult for me to carry all my stuff in my bag. So, I decided to make a laptop accessory box which would use the vertical space of the bag as well as not be bulky. I used Leather and Teak Wood for making the box.
- Tanned Leather (around 2-3mm thickness)
- Teak wood (15mm)
- 3 MDF pieces (2mm) or any flat and thin wood pieces
- Nails (1.5mm)
- Synthetic rubber adhesive
- Coconut oil
- Coffee powder
- Sand paper
- Anabond CYNO -555M adhesive
Tools and machines used:
- Wooden Mallet
- Drill with (1.5mm drill bit)
- Band saw
- Paper cutter
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Step 1: Cutting of Wood and Mdf Pieces
Cut TWO 1.5mm teak wood pieces with the dimensions as shown in the picture above and also THREE 2mm MDF pieces with the dimensions as shown in the picture above. (can increase or decrease the dimensions according to the requirements)
Sand the rough edges with sand paper to make it smooth. DO NOT sand the edge as it will give a fillet to the edges and leather won't fit properly (edge to edge) hence giving a gap in the edge of the whole product.
Step 2: Fillet the Corners
Mark a 2cm by 2cm SQUARE on all the FOUR corners of BOTH the Teak Wood pieces.
Make a curve from both of the point of intersections on all the four edges of both the pieces of teak wood. (the fillet can vary according to the choice)
Sand the extra part of the square to give the fillet to the corners.
Step 3: Making Cuts to Fix the Mdf Pieces
Making three cuts with the help of chisel and hammer to fix the THREE mdf pieces, so that after fixing all the three strips of mdd the surface will not be uneven allowing the leather to take a clean shape with out any gaps. The cuts are made to remove the material with measurements of the three MDF pieces which is 7.5cms at the left of the teak wood blok, 4.5cms at the bottom and 5cms on the right side of the block. (as shown in the picture above)
After joining all the pieces, a frame will be formed which will act as the frame of the box.
Leather will be wrapped on this frame.
Step 4: Cutting and Sticking of Leather
Cut the leather into two pieces to have a clean edge.
Make a 120 degree angle cut on the edges from where the leather will be joined (first on the top of piece A and then on the bottom of piece B) so that after joining it becomes one surface rather than having uneven.
Join the two leather pieces with synthetic rubber adhesive (on both the sides) to have one long piece which will further be wrapped on the frame made in previous step. (no need to do this step if the leather is long enough to be wrapped but should have extra in order)
Wait for 5-10 mins after applying the glue. then stick the two pieces. (Do the same further in the process where ever synthetic rubber adhesive will be used)
Cut the breath of the leather as to the frame size so that is matches edge to edge. (in this case it is 21.5 cms, the length of the MDF pieces)
Step 5: Making the Lock Flap
Cut out a rectangular piece on one of the end of the long piece of leather.
Mark the vertical lines of the rectangle on the other end of the piece. (make sure the cut is little bit lower as shown in picture two so that when it is wrapped on the frame it comes on top of the mdf piece (5cms) in order to give it back support so that it does not tear over time, the line marked with red is where the mdf board starts.)
Cut a strip of leather same in the size as of the cut out rectangle but longer on both the ends. It will act as a buckle for the strap to hold the leather in place.
Cut out the marked lines with the thickness that of leather so that the leather strip passes through that gap.
Pass the strip keeping it loose in front (like a loop) and then sticking it behind with synthetic rubber adhesive (shown in picture two and three)
Cut a strap of leather broader at one end and narrow at the other and give fillet to the corners of it. (enough to pass through the loop and is not loose)
Sick the strap with synthetic rubber adhesive little bit up than the cut out rectangular piece. (shown in picture four)
Step 6: Stitch the Leather Pieces
Drill holes with 1.5mm drill bit on the marked points on the flap.
Mark points with the distance of 0.5 cm along the midline of the area where two leather pieces are attached.
Drill holes on those points.
Stitch the leather piece with a thick thread (colour is optional).
This will hold the joined pieces more strongly and will prevent them from tearing over the long period of usage.
Step 7: Sticking of Leather to the Frame
Place the frame correctly on the leather and apply the synthetic rubber adhesive on both the surface.
Start with the bottom, mark the thickness of each mdf piece on leather (4.5cms, 5cms, 7.5cms) and stretch the leather while sticking to avoid air bumps.
DO NOT apply adhesive more than the area of respective MDF pieces on leather, as the uncovered area will also get the mark and will not look good.
On the top of the box stick the leather less than half for easy access.
Step 8: Nailing the Edges
Nailing the edges will keep the leather attached to the frame and will prevent it from coming off.
Mark points on both the edges of the box. ( Keep the points in centre of the thickness of Teak wood pieces which is 1.5 cms )
Drill on these points with 1.5mm drill bit.
Nail the nails with the help of wooden mallet.
Step 9: Poilishing Leather and Teak Wood
Taking coconut oil in cotton and rubbing it on leather will give a darker tone to the leather.
Staining the Teak Wood with coconut oil and coffee would give a darker tone to the wood surface.
After doing these two process keep the product in sun for one hour and then again repeat the same process of polishing and again keep it in sun.
And you are done!!
Enjoy using self-made laptop accessory box.