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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!

  1. Select a board so that all four sides can be left in one long piece.
  2. Cut to length on the radial arm saw.
  3. Joint one edge.
  4. Rip the other edge on the table saw. The board should now be parallel.
  5. 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.
  6. Belt sand the inside of the board. That is the side with the groove (s) cut in it.
  7. Now is the time to cut the board into pieces. It should NOT have been cut into pieces before now.
  8. 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.
  9. Stack cut the second two boards. Remember that the opposite sides of a box or frame need to be exactly identical in size.
  10. 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.
  11. Layout and drill three holes to install screws at each corner. Remember that the first hole needs to be drilled on the drill press.
  12. 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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