Complex box is probably one among easiest plans you should try. While it isn’t hard to make, it can be totally functional and beneficial for a daily use. Read the insturction below to learn making it.
Step 1. Make the layout of the paper window before cutting the boards. Once the paper windows are ready, place them onto the wood. This layout will be used to make the box pieces. The window in the paper layout is used to help you identify the grain patterns of each piece before starting to cut the board for its final size.
Step 2. Miter all sides and edges of the box on the table saw using the table saw sled. First thing to do is to miter all ends of all box parts. Then, use the clamp onto the stop block and the sled when you start cutting another ends of the box parts.
Step 3. Make the feet on each end and side using ¾” bit in the router table. Place some stop blocks to set the limit of the cut length. One way that you can do to avoid the grain leaving from the feet is by creating three stages of cutting. Each stage will have 1/8” raising bit.
Step 4. Insert some clamping jigs onto the sides and ends of the box. The jigs are fortunately shorter than the box pieces so that these jigs don’t obstruct the joint when assembling the pieces altogether.
Step 5. Insert spring clamps into each corner of the box. Adjust the position of the pieces to make square shape of the box. Then, glue all joints before attaching the bottom piece and the final sides. Make sure that all pieces are nicely and evenly square.
Step 6. If you think that the box is not even, you can sand the box feet onto one sheet of sandpaper with 80-grit. You can also make the top surface leveled using the same method. Sand all pieces until you are sure that they are all smooth and even.
Step 7. Build the carriage for box supports when you cut the corner slots. These corner slots are dedicated for the keys. Attach 90-degrees blocks into the carriage sides using some screws.
These blocks are temporary and they can be removed after the work is done. Make the blocks to hold the seat boards so that these boards are only touching the box ends. Before using the carriage, remove the blocks.
Step 8. Make the key slots throughout the mitered corners. Firstly, cut the center slots. Raise the bit for the slots and then add ½” spacer for the slots. Then, insert second spacer, raise it, and cut.
Step 9. Cut the wood strips dedicated for the keys with small sled using table saw.
Step 10. Cut the keys triangularly using a band saw. Then, place these keys into the wood strip as shown in the picture. The grain will be in the same direction with all keys.
Step 11: Glue all keys into the inside of the slots. Make sure that the keys are inserted into the slot bottoms. Use a small block to push any keys which are not fitted appropriately into the slots.