Box Packaging

There are 4 main parts

The main box, the box lid, the box insert and your puzzle maze

Custom measurements

The box you built should match the size of your maze so that it fits perfectly.

Box inserts line the box

The insert will sit on the base of the main box and act as a liner.

Follow these 12 steps to successfully build your own box

Step 1

Paper template to measure the correct dimensions. Lay your maze puzzle over the paper cut out to see if it fits.

Use the guillotine

Don't forget you need extra space for the box walls as well so make your box a little bigger. Use a metal ruler - The extra space on each side should be the width of a metal ruler.

Step 2

Do not stick your card template on your MDF, but trace or transfer the template dimensions onto your MDF base.

Notice the extra space inside the rectangular box shape around the puzzle maze.

Step 3

Use the scroll saw to 'rough-cut' your base outline.

Leave a little extra on the outside of the box for sanding later.

You will need to make a second copy of the base for the top.

Cut 2 pieces - the base and top.

Step 4

Measure 4 lengths of side wall. If your box is square, then all 4 will be the same length otherwise you will have 2 pairs for your rectangular shape.

Use a ruler and coping saw for this job.

When finished, lay out your 4 wood walls and base like the photo.

Step 5

Miter cut each corner but remember to cut the correct side of the wood - it should be on the inside of the wood. Use a coping saw or set up the bandfacer to saw the angle perfectly.

Ensure the lengths of wood or pairs are matching in length.

Step 6

Use wood glue to assemble the base and 4 side walls of your box.

Use masking tape around the corners and taped over the base to hold it in place while its drying.

Using the vice can help hold it in place while it dries.

Step 7

Prepare you lid. Measure and mark out the correct size to fit your box.

Cut out your lid using the scroll saw but remember to cut on the outside of the line so that you can sand later.

Glue your finished lid to your base on top of the side walls to make a sealed/closed box.

Step 8

Designing your lid. There are many different ways to design your lid. Some will take longer than others but all should look great.

Laminate your MDF with veneer.

Drill or cut out a design and fill holes with resin.

Use scrap material and cover in resin.

Use a vinyl sticker sheet when clamping between your veneer face and the vice.

Step 9

Use the bandfacer to sand and tidy all edges before cutting.

Your teacher will cut/slice your box into 2 pieces down the side so that you have the lower part of the box and the top lid.

Step 10

Cut and prepare your inner lid walls. These will sit inside the box and hold the lid in place so that it doesn't slide off.

Remember, this will reduce the internal space available inside the box, so if you didn't make the box a little bigger than your maze puzzle, your maze puzzle wont fit inside!

Step 11

Glue only a few key spots of the inner lid walls to hold it in place.

If your measuring, cutting and sanding was accurate, then you should already have a tight fit.

Step 12

Measure and cut your box liner to sit on the base of the box. Your maze puzzle will sit on this.

Class example with matching foam liner (step 12) and coloured inner walls (step 10). At this stage the wooden box has already been oiled with Teak oil.

A small gap between the lid and the box creates a nice effect and makes it easier to remove the lid. Adding colour to this inner wall can also improve the design and over look.

Student example: Finished

Student example: Unfinished

Student example: Unfiinished

Testing a resin pour lid. Resin was colour a dark green and poured over the unfinished box. Gold and green pigment was then sprinkled over the wet resin.

This should happen at step 8 before sanding the edges.

Student example: Unfinished

The same green resin was poured over the top MDF lid but orange pigment was sprinkled over the wet resin to create the effect.

A small toothpick stick swirled and dragged the orange pigment around.

Student example: Unfinished

Wooden veneers can also be glued and pressed onto the top MDF lid panel. This dramatically improves the look of the box as it hides the MDF layer and shows the grain of the hard wood.

Teak oil should be used after to bring out the wood grain.