Plywood Box Instructions

Set the items you want to store in your box on top of a sheet of 3/4-inch plywood. Draw a rectangle around them that is slightly larger than the items. Use a T-square to square the edges. This is the bottom of your box.

Measure the height of the items, and add 1-inch to determine the height of the four sides.

Cut the bottom of the box out with a table saw.

Measure and mark two rectangles on your plywood for the two long sides of the box. Their length should be 1 1/2 inches longer than the long edge of the bottom and 1 3/4 inches taller than the items being stored. (The extra 3/4 is for the bottom of the box.) Use your T-square to square the edges, and cut the pieces out with a table saw.

Measure and mark two more rectangle for the ends of the box. They should be exactly as wide as the shorter sides of the bottom piece and as tall as your long sides from step 4. Use your T-square to square the edges. Cut the pieces out with your table saw.

Apply a line of wood glue to the edges -- on the short sides only -- of your plywood bottom panel. Stand one end piece up against the edge, and push it against the side of the panel. Make sure that the edges of the two panels are flush. Secure the end panel by nailing one 1 1/2-inch pin nail every 3 inches through the side panel and into the width of the bottom panel.

Repeat the process in step 6 at the opposite end of the box with the remaining end piece.

Apply a line of wood glue along the edges -- the long sides -- of the bottom panel, and to the upright edges of your end panels. Fit the side panels into place one at a time. Press them up against the glue, and make sure that their ends are flush with both the bottom of the box and the two end panels.

Nail one 1 1/2-inch pin nail every 3 inches through the side panels of the box into the edges of the two end panels and the two sides of the bottom panel.

Sand the box thoroughly with 100-grit sandpaper on a random orbit sander to remove any splinters from the edges of the plywood.