TOC Box Making Bonanza1 - Popular Woodworking Magazine

3
skill level: basic
what’s
cookin’?
WHEN I WENT AWAY TO COLLEGE, my mother sent copies
of all her recipes with me. I still
have them and have enjoyed
making the food that gave me
comfort as a child. This box is
made to hold 3" x 5" (76mm x
127mm) note cards. I know a
lot of recipe cards are 5" x 7"
(127mm x 178mm), so add the
necessary dimensions if this is
the case with your recipes. Of
course, you can use this box as
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a jumping-off project to create
a series of boxes to hold note
cards with secret recipes, notes
for your family-history project
or your next great novel.
This project is made differently from the previous projects
— the sides and ends are glued
together, then the top and bottom are attached. This makes
a totally enclosed box. The lid
is then cut from the assembly.
Doing it this way ensures the lid
will fit perfectly and the wood
grain will match.
This project demonstrates
another way to keep a lid in
place. A lip is created by attaching the liner panels inside the
box and letting them extend
past the top edges of the sides.
This gives the lid something to
grab on to. I put hinges on this
box just make it a little easier
to open and close the box without losing the lid.
Top A
End liner E (2)
Side liner D (2)
Bottom A
Side B (2)
End C (2)
Plan section view
1/8”
(3mm)
3/8”
10mm
liners
3 1/4” (83mm) -wide stock allows
for 1/8” (3mm) -wide saw kerf
so final width of sides and ends is 3 ”.
3 1/4”
1/2”
13mm
3”
83mm
76mm
3/8”
10mm
3/8”
10mm
61/8”
155mm
1/2”
13mm
3”
76mm
3/8”
10mm
7 1/4”
184mm
3/8”
10mm
3/8”
10mm
3/8”
10mm
5 3/8”
137mm
3/8”
10mm
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THICKNESS
(mm)
WIDTH
(mm)
LENGTH
1
1 pair1" x 11⁄ 2" (25mm x 38mm) brass butt hinges
STOCK
QUANTITY
A
Hardware & Supplies
PART
REFERENCE
inches (millimeters)
(mm)
top and bottom
red oak
3⁄
8
(10)
61⁄ 8
(156)
8
(203)
Tools needed
8
(10)
31⁄ 4
(83)
8
(203)
hand saw with miter box
spray or wipe-on lacquer
B
2
sides
red oak
3⁄
C
2
ends
red oak
3⁄
8
(10)
31⁄ 4
(83)
53⁄ 8
(137)
60-, 100-, 120-, 150- and 220-grit sandpapers
D
2
side liners
red oak
1⁄
8
(3)
31⁄ 8
(79)
71⁄ 4
(130)
No. 0000 steel wool
red oak
1⁄
(3)
1⁄
(79)
1⁄
(130)
sanding block
D
2
end liners
8
3
8
5
8
block plane
bench plane
random-orbit electric sander (optional)
1
Once you’ve got the parts cut, lay out the sides and ends. Add
glue and clamp the ends between the sides.
3
When the glue is dry on the end/side assembly, attach the top
and bottom parts. You now have a box.
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2
Measure the diagonals. When they’re equal, the box is square.
4
Use a stationary sander or hand sand the box smooth.
5
Cut the lid from the box. The dimensions for the width of the
sides and ends in the cutting allow for the width of the saw
blade kerf. The box will still be deep enough to hold the 3" ×
5" (76mm × 127mm) note cards.
6
Here’s how the lid should look. It has a small lip that will match
up with the liner sides.
8
When the glue has dried, put the lid on the box, clamp the whole
thing together and give it a final sanding.
7
Fit the side liners first, then fit the end liners between the
side liners. Use your trusty spring clamps to glue the liners
in place.
9
5
After the finish is applied, you can add hinges if you like. To keep
it simple, attach the hinges directly on the back of the box. Now
get those recipes organized and start cookin’.
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