Marking Out

Tools required - Rule, Try Square, Sharp pencil

Step 1: Using a rule measure from end of timber and with a sharp pencil place a mark at 200mm, 5mm, 200mm, 5mm, 90mm, 5mm and 90mm.

Step 2: Use the try square, hold stock against timber. Place your pencil on the first mark, slide the try square up to it and draw a line.

Squaring ends

Tools required: Disk sander and try square.

Step 1: Use the fence on the disk sander to support and hold the timber square.

Step 2: Sand up to your pencil line. Do not sand the line off.

Step 3: Check both sets of sides and ends are equal in length and square across end.

Mark and drill for nails

Step 1: Using a rule, try square and pencil measure 6mm in from each end of the two long side pieces and mark a line.

Step 2: Measure from the bottom of the long sides and place a mark on your line at 10mm.

Step 3: Measure from the mark and place another mark at 25mm.

Step 4: Drill pilot holes using a nail.

Note: The housing (groove) is on the top of the box and is on the inside face, so all of your marking is done on the outside face, just like in the photo opposite.

Reduce one end

Step1: Using a tenon saw and bench hook cut the groove off one end and sand smooth so it fits flush with the housing for the lid (the groove) on the two sides.

Note: the offcut can be used as a ‘handle’ to open your lid.

Sanding Inside faces

Step 1: Using a sanding block and sandpaper sand all inside faces and edges smooth to prepare them for nailing. Begin with 120 then 180 and 240 grit sandpaper.

Note: DO NOT SAND THE END GRAIN.

Assembly

Step 1: Glue and nail one side to the ends. With ends facing up wipe off excess glue with a damp rag.

Step 2: Glue and nail the second side to the ends. Again remove excess glue.

Step 3: Use a hammer and nail punch to punch nails just below the surface. Fill holes with a small amount of timber putty.