We need materials:
- Six 2x4x96" boards
- Two #2 1x6x96" boards
- One #3 1x12x96" board
- One sheet 5.2mm import hardwood plywood 4'x8'
- Five 1/2x48" dowel rods
- One 3/8x24" dowel rod
- Two hinges
- One lid support (commonly called a safety hinge)
- 2" wood screws
- 8d finish nails
- Wood glue
Cut List
A: 5 – 2x4x40" Rails for front frame, back frame and top rail for backrest.
B: 1 – 2x4x35" Cross rail for backrest. *
C: 4 – 2x4x14" Rails for side frames.
D: 8 – 2x4x13" Stiles for front, back and side frames. *
E: 2 – 2x4x29" Stiles for backrest. #
F: 2 – 33 3/4x11 3/4" 5.2mm plywood for front and back panels.
G: 2 – 7 3/4x11 3/4" 5.2mm plywood for side panels.
H: 2 – 40" Pieces of #3 1x12 for floor panel.
I: 4 – 42" Pieces of #2 1x6 for lid.
J: 1 – 2x4x38" Support rail for lid.
K: 16 – 1/2" diameter dowel rods. Length will be determined at a later stage during assembly
Prepare the Lid and Floor
1. Edge glue and clamp three of the #2 1x6x42" pieces (I) together for the lid. Use dowels in the edges of the boards to strengthen the joints.
2. Edge glue and clamp the #3 1x12x40" pieces (H) together for the floor. Use dowels in the edges of the boards to strengthen the joints.
Build the Box
1. Cut blind, 1" long by 1/2" thick tenons in both ends of each front, back and side frame stiles (D) and both ends of the backrest cross rail (B).
2. Cut blind 1" long by 1/2" thick tenons in one end of each backrest stile (E).
3. Rout or cut a 1/2" deep by 5/16" wide groove in one edge of each front, back and side frame stile (D).
4. Rout or cut a 1/2" deep by 5/16" wide groove in one edge of each side frame rail (C). Rout or cut a 1/2" deep by 5/16" wide stopped groove in one edge of each front frame and back frame rail (A). You should only make the groove in four of the five 2x4x40" rails. The fifth one is the backrest top rail and doesn't need a groove. The grooves in the rails should stop just short of either end of the rail so they aren't visible from outside the toy box.
Stopped groove in rail.
Style receiving panel
5. Lay out the pieces for the front and back panels. Mark the rails (see image at right) and cut mortises to receive the stile tenons.
6. Dry fit the front and back frames with the 5.2mm plywood panels in place. Trim any of the parts as needed.
7. Glue and clamp the front and back frames with the panels in place.
8. Lay out the pieces for the side panels. Mark the rails and cut mortises to receive the stile tenons.
9. Dry fit the side frames with the 5.2mm plywood panels in place. Trim any of the parts as needed.
10. Glue and clamp the side frames with the panels in place.
11. Rout or cut a 7/8" wide by 1/2" deep groove on the inside face of the bottom rail of each front and back frame. The groove should be 1" up from the bottom edge of the rail and stop just short of the end so it's not visible from outside the toy box.
12. Rout or cut a 7/8" wide by 1/2" deep groove on the inside face of the bottom rail of each side frame. The groove should be 1" up from the bottom edge of the rail and extend the full length of 13. Butt the back edges of one side frame to the inside face of the back frame. The outside face of the side frame should be flush with the end of the back frame. counter sink screws through the back frame into the side frame to secure it in place. Secure the second side frame to the opposite end of the back frame.
14. Trim the floor piece from step 2 to 14 7/8 x 37 7/8" and slide it into the groove in the bottom of the assembly.the rail.
