DIY Make Two Utility Boxes Using One Sheet of Plywood

Wooden storage boxes command high prices in big box stores. You can make two wood storage boxes from one sheet of plywood for less than $50 and a few basic tools. Use them to store anything you can think of, from blankets, winter clothing, toys, tools or more.

This plan is inspired by a Canadian plywood design. It ingeniously uses one sheet of ¾” plywood to make two chest-type boxes.

Construction is the same for both boxes. The finished box dimensions are A: 31 ½” long by 18: deep by 16 ¾” high, and B: 25″ long by 14 ½” deep by 13″ high.

You will need:

· One 4-by-8 sheet furniture grade ¾” plywood · Edge tape (optional) · Wood putty or wood plugs · Stain or primer and paint · Sandpaper in varying grits · Jigsaw, table saw or circular saw with plywood blades · Drill with bits, including countersink bits · Wooden or rubber feet, or locking casters (optional) · Construction adhesive · Chest hinges (locking is preferred, especially if children are using the chest) · Lock and hasp (optional) · 1 ½” Forsner bit or hole saw · Measuring tape, markers, straightedge · One box #8 wood screws

Notes:

· To save time, sand the entire plywood sheet on both sides before cutting. · Clamp scrap wood pieces to the underside of the cut lines to minimize tearout. · Always follow the safety instructions for any tools, and use the proper safety gear. · Before securing with screws, apply construction glue first. Remove squeeze out with a rag. · These chests are made with butt joints, but dovetail joints can certainly be used. · Make the original chests first, then customize your pattern and make them your own. · With decorative molding, paint and stencils, you can make gifts for everyone on your list that are sure to become heirlooms. · Change a child’s toy chest into a teen’s storage area with paint and a few stickers. · Less expensive grades of plywood may be used however; this may require more wood putty to smooth the surfaces. · Using less expensive grades of plywood creates an interesting surface that suggests “old-time” construction. Seal the wood and paint carefully to retain the character, but eliminate edges that fabrics won’t catch on. · Instead of hand holes, cut two separate circles and use rope handles. · Instead of an arch, cut the top side edges in any fancy shape desired.

Step One:

Lay the sheet of plywood on a flat surface and ensure it will not wobble. From the first long side, measure and mark a line 16″ from the edge running the length of the board.

Make a mark 12″ from the other edge 70 ½” long. From the end corner, measure 14″ from the side, and make a mark 23 3/8″ long. This will make a box shape.

This will leave a strip 19.5″ wide for most of the center.

Cut these pieces precisely. Sand the cut edges.

Step Two:

From the 16″ wide strip, cut three boards, each 30″ long. Label two boards as “Side A” and the third board “Bottom A.”

From the 19.5″ wide strip, cut two boards 18″ long, one board 18″ by 27 7/8″, and two boards each 15 ½” by 14″. Label the first two boards “End A,” the second board “Top A,” and the third board “End B.”

From the last strip, cut three boards each 23 ½” long and label two as “Side B” and the third as “Bottom B.” Cut the last piece 14″ by 23 3/8″ and label as “Top B.”

Sand the cut edges and stack the pieces according to their respective boxes, A and B.

Step Three:

Gather the end pieces to mark for the hand holes. Locate and mark the center of the boards at the top. Make a mark 1″ down from the top, and another mark down 1 ½” from that. Make a line 4 ½” long on each of these marks, the sides being equal distances from the center mark.

Drill two or more holes in the center of these marks, and then use the jigsaw, chisels, etc to create the hand holes. Sand smooth.

Make a mark 2″ down from the top corner edges and using a plate or other curved surface, mark a curve and cut on both sides. The result is a curved edge. Sand the edges smooth.

Re-stack the pieces with their respective boxes.

Step Four:

Begin with the pieces from Box A. Place “Bottom A” on the floor, good side up. Butt the side pieces against the bottom length, good sides out. Glue the edges, clamp and attach with screws.

Butt the end pieces against the ends, glue, clamp and screw in place. Make sure the good sides face outward.

Place the top on the box with the good side facing up. Mark the hinge placement 3″
in from each side. Mark the placements on the box and the top. Attach the hinges to the box and top. Open and close to ensure nothing catches.

Step Five:

Attach chain stays if desired to keep the box top from going all the way back. Locking hinges work well for children to protect little fingers from the box top hitting them.

Prime and paint or stain in the color desired. Attach feet or casters, if desired.

Construct box B in the same manner.

Store anything desired in your new box.

These boxes will last for decades with minimal maintenance, and everyone you know will want one, or two. Make them as sets for friends and family.

Source: Staff article, “Easy Blanket Chest,” Canply Canadian Plywood website, no date given


People also view

Leave a Reply

Your email address will not be published. Required fields are marked *