This simple wooden box with mortised hinges was created by Jesse from Penalty Box Woodshop, and it’s a great way to get started with woodworking. Follow this step-by-step guide to create your own beautiful box that can be used for jewelry or keepsakes.
Materials and Tools Needed
- Figured maple for the box
- Walnut for the top and bottom panels
- Wood glue
- Shellac for finishing
- CA glue and accelerator
- Sandpaper (100, 180, and 220 grit)
- Painter’s tape
- Various saws (table saw, miter saw, band saw)
- Trim router with a quarter-inch straight bit
- Chisel
- Self-centering bit
- Clamps
Step 1: Cut the Wood
Start by selecting some figured maple and cutting it down to a more manageable size. After trimming the rough edge at the table saw, cut the sides to length using the miter saw. Make sure to cut the sides in order to maintain a continuous grain pattern around your box.
Step 2: Measure and Number the Pieces
Set the boards upright on your workbench to determine the desired height of the box. Once you have your measurement, return to the table saw and cut the box sides to their final width. Number the boards for easy reference throughout the build.
Step 3: Prepare the Top and Bottom Panels
Cut an oversized piece of 3/4 inch walnut for the top and bottom panels. Use the band saw to resaw the walnut in half and then bring it to the final thickness on the planer. Set these panels aside for later use.
Step 4: Cut Dados for the Panels
Set your table saw blade to a quarter-inch high and cut a dado at three-eighths of an inch from both the top and bottom edges of each side of the box. Repeat this for the top and bottom panels. Make small adjustments until you achieve the perfect fit.
Step 5: Sand the Pieces
Now that all pieces are cut, sand them to 180 grit. This will prepare them for a smooth finish once the box is fully assembled.
Step 6: Cut 45-Degree Angles
Set your blade to cut a 45-degree angle and use a fresh board to create two minor gauges for accurate cuts. You can now align each side piece and cut perfect 45-degree angles without losing length.
Step 7: Assemble the Box
Lay the side pieces in order and face down. Use painter’s tape over each joint, ensuring the tips of each board touch and the edges align. This tape will act as a hinge for easy assembly. Measure for the top and bottom panels, remembering to add a half-inch to your measurements. Cut these panels to size and assemble the box with wood glue, using clamps to secure the miter joints.
Step 8: Shape the Box Edges
After a few hours, remove the clamps and set your band saw fence to one inch from the blade. Cut the designated edge to create the top of the box. Use CA glue and sandpaper to remove any bandsaw marks and keep each edge nice and flat.
Step 9: Chamfer the Edges
Using a mini chamfer bit, create a slight chamfer on the outside and inside edges of the box. This adds a nice touch and helps distinguish the top from the rest of the box. For areas where the chamfer bit can’t reach, use a chisel to match the rest.
Step 10: Install the Hinges
Mark the hinges using a marking knife and set your trim router to remove most of the wood, stopping just short of your line. Use a chisel to finish removing the waste for a clean fit. Repeat this for the second hinge and the top.
Step 11: Final Assembly and Finishing
Drill pilot holes for each screw using a self-centering bit and drive them in by hand. For the finish, apply shellac to bring out the figure in the maple. After three coats, your box will look fantastic!
Now you’ve created a beautiful wooden box with mortised hinges!
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