Create a 100% functional box from foam and veneer, using nothing more than a utility knife and a little ingenuity!
Step 1: Cutting the Foam Board
The first thing you need to do is cut the foam board for the 4 sides out of 1/2" thick foam board. Your box can be any size but for this example I've cut mine to 3.25" tall. We'll cut to length in a future step.
Step 2: Cutting the Veneer
Now you'll want to cut a piece of paper backed veneer slightly oversized. We'll trim it down to it's final dimensions in a couple of steps. Currently we're only veneering the inside of the box as it's easier now.
Note: The veneer you choose must be a paper backed. Regular veneer will be harder to work with and not flat.
Step 3: Attaching the Veneer
Using 3M 90 spray adhesive you can now attach your veneer to the 4 pieces of foam board.
Note: You may see me using 3M Super 77 adhesive in the photographs but I found that 3M 90 works better.
Step 4: Trim to Size
Now you can cut off the excess veneer and cut all pieces to length. Your box can be any size but for this example my pieces will be:
Two - 8" x 3.25"
Two - 4.5" x 3.25"
Step 5: Hot Gluing the Box
Now using a hot glue gun you can glue the 4 sides together with the veneered sides facing the inside.
Step 6: Adding the Bottom
For the bottom I'm using 3/16" foam board that I veneered on one side. Again, hot glue this in place with the veneered face on the inside.
Step 7: Veneering the Outside
Now that the box is assembled and the inside is veneered we can start veneering the outside. This will cover up all your glued joints and start to give it a solid wood look!
Step 8: Veneering the Top
We want to give the illusion of a mitered joint so cut your veneer to width and length with 45 degree angles. I glued these pieces on with CA glue (super glue).
Step 9: Making the Lid
For the lid I cut a piece of 1/2" foam board that'll overhang the box. The underside of the lid has a 3/16" piece glued on that'll fit inside the box for a nice fit. Your lid can be any size but in this example my lid is the following dimensions:
9" x 6.5"
Step 10: Flocking
For the underside of the lid I chose to flock with with black fibers instead of veneering. You'll find plenty of great flocking tutorials here on Instructables.
Step 11: Finishing Touches
I finished my box with boiled linseed oil. Instead I would suggest using spray lacquer because the oil can soak through and ruin the foam board. I've also added a pull knob to the top that I got from my local home center.
Step 12: That's It! You're Done!
That's it! You're done! This is a simple project that doesn't require many tools or even a workshop. Be sure to watch the YouTube video for extra tips and visuals.