DIY Paintbrush Box Cases

Cutting Pieces

• Plywood is the simplest material available for case construction. Use 1/2-inch thick plywood to allow the nails to be driven into the edges of the case pieces. Cut two sides identical in size, and cut one top and one bottom the same length as the side pieces. Cut two ends the same width as the top and bottom and 1 inch taller than the side pieces, using a table saw. Size the pieces according to the length and width of the brushes.

Assembling the Case

• Use wood glue and a pin nail gun to assemble the case. Fasten the top and bottom, overlapping the edges of one side. Fit the remaining side piece between the top and bottom. Glue and nail the ends of the case in place. Use 1 1/4-inch pin nails to fasten the parts in place. Allow the glue to dry completely before making the cut to create the lid of the box.

Cutting the Lid

• Set your table saw to 1 inch deep and the fence 1 inch from the blade. Cut the box along its length down one side. Flip the box over and cut one end. Cut the remaining side, before turning it for one last cut through the remaining end to remove the box lid, which will be 1 inch deep. Sand the edges of the lid and the top edges of the box smooth with 150-grit sandpaper.

Adding the Hardware

• Cut a piece of piano hinge to fit the length of the box using a hack saw or a pair of tin snips. Fasten it to the lid and box side with 1/2-inch wood screws and a cordless drill. Attach a utility handle to the top of the case. Fasten a box clasp to the opposite side of the case, bridging the cut between the side of the case and the edge of the lid with wood screws.