This project is by Newton Makes, who expertly combines various woodworking techniques into a functional and visually appealing design.
Whether you’re a seasoned woodworker or a beginner, this tutorial will provide you with all the steps necessary to build your own storage box.
Step 1: Gather Your Materials
Before diving into the woodworking process, it’s crucial to gather all the necessary materials and tools. This project primarily uses two types of wood: walnut for the body and maple for the lid and splines. Here’s what you’ll need:
- Air-dried walnut slab
- Maple slab
- Titebond wood glue
- Osmo Top Oil for finishing
- Woodworking tools (table saw, router, bandsaw, etc.)
- Moisture meter
- Combination square
- Sanding materials (120 and 180 grit sandpaper)
Having all your materials ready will ensure a smooth workflow throughout the project.
Step 2: Design the Box
Next, sketch out your design. The dimensions for this box are approximately 20 inches long, 10 inches wide, and 3.75 inches tall.
This size accommodates a laptop while leaving room for a mouse and other accessories. The box will have a divider to separate the laptop from the charging cables. Maple splines will be used in the corners for aesthetic appeal and to strengthen the joints.
Step 3: Prepare the Walnut
Now it’s time to prepare the walnut slab. Use a moisture meter to check the wood’s moisture content. Ideally, it should be around 8 percent for air-dried walnut. If the moisture content is too high, allow the wood to acclimate in your workshop for a few days.
Once ready, cut the walnut into rough sizes, ensuring you leave extra material for milling later. This approach helps prevent any cupping or warping during the drying process.
Step 4: Mill the Wood
After the walnut has acclimated, it’s time to mill it down to its final thickness. Aim for about 5/8 inch. Use a table saw to ensure clean cuts, and check the joinery as you go. Miter joints will be used for this project, which provide a seamless appearance.
Once the pieces are cut, it’s essential to create a groove in the inside face of each piece to accommodate the box bottom. This will help secure the base of the box.
Step 5: Create the Dado for the Divider
Before gluing everything together, you need to cut a dado on the inside face of the longer pieces for the divider. This will help keep the cables separated from the laptop. Using a router table is an effective way to achieve precise cuts.
Step 6: Assemble the Box
With all the pieces prepared, you can now assemble the box. Apply Titebond wood glue to the miter joints and carefully join the pieces together. Make sure to clamp the box and allow it to dry thoroughly. Patience is key here, as you want the joints to be strong and secure.
Step 7: Add the Rabbet for the Lid
After the box has dried, cut a rabbet on the inside edge to allow the lid to sit comfortably inside. This can be done with a table saw or a handheld router. This step is crucial as it ensures that the lid will fit properly and not create any pressure on the box as the wood expands.
Step 8: Install Maple Splines
The next step involves adding maple splines to the corners of the box. Using a spline jig will make this process easier and more accurate. The splines not only enhance the aesthetics of the box but also provide additional strength to the joints.
Step 9: Create Cushioning for the Interior
To protect your electronics, consider adding some cushioning to the interior of the box. Choose a fabric that not only looks good but also provides a protective barrier for the laptop and cables. A piece of fabric that resembles leather can add a luxurious touch to your project.
Step 10: Prepare the Lid
Now it’s time to work on the lid. Cut a piece from the maple slab, milling it down to the appropriate thickness and size. Ensure there is enough space for the lid to fit comfortably without being too tight.
Consider the design of the handle at this stage. A simple yet elegant handle can be made from a rectangle of walnut with an inlay of maple, reflecting the splines used in the corners. This not only ties the design together but also provides a cohesive look.
Step 11: Finishing Touches
Once the box and lid are complete, it’s time to apply the finish. Osmo Top Oil is a great choice for this project, as it provides a durable and attractive finish. Apply it evenly using a finishing applicator pad, following the manufacturer’s instructions.
Step 12: Final Assembly and Enjoy!
After the finish has dried, assemble the final components of the box, including the handle. Take a moment to admire your work! This box is not only functional but also a testament to the skills and techniques you’ve mastered throughout the project.
Congratulations on completing your custom storage box! You now have a stylish and practical solution for organizing your laptop and accessories, all thanks to the guidance of Newton Makes.
