Somewhere in the neighborhood, someone is building a box. This is old news.
Bill of Materials
3 — 4′x8′ Sheets of 5/8 Particle Board
1 Pair — 3/4 ” Lid Supports
4-1/2 feet — 2″x2″ Stock (Fir or Pine)
1 Small Box — 1/2″ Drywall Screws (Black)
1 — 3′ Piano Hinge (1/2″)
1 Bottle — Yellow Carpenter’s Glue
1 — Heavy Duty Hasp
1 — Big Lock (w/2keys — just in case)
Whatever fits — Light, Sound, Odor, Presence (For Filling)
Required Tools
Table saw, Circular saw, Mitering Chop saw,
A rechargeable Cordless drill.
Tape Measure & Carpenter’s Square,
Claw Hammer.
C-clamps, Block-clamps, Bar-clamps,
A wooden handled Rubber Mallet.
Blacksmith’s Vise,
Screwdrivers (Phillips & Standard)
An Idea.
Instructions for Construction
Prepare a clean, well-ventilated place, free of distraction, in which to work. An ordered work-space is an efficient work-space.
Step 1
Cut 4×8 sheets of particleboard using a wall mounted circular saw to the following dimensions:
Top & Bottom: 36″ square
Front & Back: 36″ square
Sides: 36″x35 3/8″
Mark the pieces accordingly.
Cut 2″x2″ stock to 24″ using the mitering chop saw. Discard scrap.
Step 2
Attach a dado blade to the table saw. Set the dado to 5/8″ width and adjust the blade height to 5/16″. Trim a notch, or dado, onto two opposing sides of the Front & Back panels.
Step 3
Join Front & Back and the two Sides. Spread liberal amounts of glue on all mating faces. Use Bar-clamps to force joints to mate. With a damp, lint-free cloth, wipe away any excess glue that has leaked out of the joints.
Use the Carpenter’s Square to judge the truth of your box’s corners. Tap the sides with the Mallet until your box comes true.
Using the cordless drill, drive a half dozen black drywall screws into each corner. To preserve integrity, the screws must enter the corners from the Front & Back sides. After one hour, remove the Bar-clamps.
Step 4
Mount the piece marked ‘Bottom’ to either end of the tube you have so far constructed. This step is much like Step 3 above in the application of glue and screws. Both should be applied liberally. Clamps are unnecessary.
Step 5
Attach the Piano Hinge to the last piece of particleboard — the one you should have earlier marked ‘Top.’
Step 6
Mount the 2″x2″ stock in each of the box’s four corners with glue and drywall screws. This stock will hold your corners square as well as provide a convenient place mount a false bottom (additional material required).
Step 7
Attach Top and Piano Hinge to the box.
Step 8
Mount the Hasp on the edge of the Top opposite the Piano Hinge.
Step 9
Attach Lid Supports to Sides and Top following manufacturer’s printed instructions.
Step 10
Fill your box with 2003 and lock it up.