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The Simple Box Project
This plan is for any sized box with a ¼" plywood bottom in it, similar to the
basic construction of a cabinet drawer. The key consideration here is to make
the size box you need without wasting any wood. No matter what you should never
waste wood. As you might guess, wood is quite
expensive. It is a lot like being at a buffet: There is plenty of wood for you
to use, but it is nicest to use all you take and take all you use. Thanks!
- Select a board so that all four sides can be left in one long piece.
- Cut to length on the radial arm saw.
- Joint one edge.
- Rip the other edge on the table saw. The board should now be parallel.
- Cut the groove on bottom of inside of board to receive plywood. (See diagram below for
details). Cut a second groove in the top of the inside if you are to have a sliding lid.
- Belt sand the inside of the board. That is the side with the groove (s) cut in it.
- Now
is the time to cut the board into pieces. It should NOT have been cut
into pieces before now.
- Stack cut your first two boards. If you do not know what stack cutting is you should
find out before you waste wood, and thus plunge your life into a never-ending bottomless
pit of horror, deceit, and lies.
- Stack cut the second two boards. Remember that the opposite sides of a box or frame need
to be exactly identical in size.
- Cut the plywood bottom to fit inside the grooves. Remember that this plywood cannot fit
tightly, but needs to have a little play in it. Finish sand and oil the plywood.
Neither the plywood nor the sides get glue on them.
- Layout and drill three holes to install screws at each corner. Remember that the first
hole needs to be drilled on the drill press.
- Assemble the box; install the woodscrews and plugs. Cut and install the small
rectangular plugs as well. The only glue used on the
project is to glue the plugs in. Do not glue the sides or the bottom.

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