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Build a Toy Box

Build a Toy Box

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Published by - yAy3e -

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Published by: - yAy3e - on May 16, 2012
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06/04/2013

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Build a Toy Box
A toy box is a treasure chest for a child. Opening the the lid opens the door to a new worldof possibilities, limited only by the imagination. If your treasured person isn't a child, thispiece also makes an attractive storage bench. A moderately skilled woodworker should beable to build this toy box with typical shop tools in two weekends for under $75. Lowe's ishappy to provide this information as a service to you.
Tools
 
Table saw
 
Drill/driver with bits
 
Router (optional)
 
 
Combinationsquare
 
Tape measure
 
Hammer
 
Clamps
 
Safety glasses
 
 
Dust mask
 
Materials
 
 
Six 2x4x96" boards
 
 
Two #2 1x6x96" boards
 
 
One #3 1x12x96"board
 
 
Five 1/2x48" dowelrods
 
 
One 3/8x24" dowel rod
 
 
Two hinges
 
 
One friction lid support
 
 
2" wood screws
 
8d finish nails
 
 
Wood glue
Cut List
(For an illustrated version of this cut list, clickhere.)
 
A: 5 – 2x4x40" Rails for front frame, back frame and toprail 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" Lauan for front and back panels.
 
G: 2 – 7 3/4x11 3/4" Lauan 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 duringassembly.
 
These instructions are designed for assembling thetoy box usingmortise and tenon joinery. If you use
 
dowel joints or simple butt joints with reinforcingscrews, subtract 2" from the cut list items indicatedwith an*and 1" from the item indicated with a#. To learn more about mortise and tenon joinery clickhere.
 
Prepare the Lid and Floor
 
1.
 Edgeglue and clamp three of the #21x6x42" pieces (I) together for the lid. Usedowels in the edges of the boards to strengthenthe joints.
 
2.
Edge glue and clamp the #3 1x12x40" pieces(H) together for the floor. Use dowels in theedges of the boards to strengthen the joints.
Boards prepared for gluing.
 
Build the Box
 
1.
Cutblind, 1" long by 1/2" thicktenonsin bothendsof  each front, back and side framestiles(D) and both ends of the backrest crossrail(B).
 
2.
Cut blind 1" long by 1/2" thick tenons in one end of eachbackrest stile (E).
 
 
3.
Rout or cut a 1/2" deep by 5/16" widegroovein one edge of eachfront, back and side frame stile (D).
 
4.
Rout or cut a 1/2" deep by 5/16" wide groove inone edge of each side frame rail (C). Rout or cut a1/2" deep by 5/16" wide stopped groove in oneedge of each front frame and back frame rail (A).You should only make the groove in four of the five2x4x40" rails. The fifth one is the backrest top railand doesn't need a groove. The grooves in the railsshould stop just short of either end of the rail sothey aren't visible from outside the toy box (seeimage at left).
 
Stile receiving panel.
 
Stopped groove in rail.
 

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