How To Build A Wood Box

Choosing the Wood

• Figuring the wood: Most figure is on the bark side.


• Wood defects: The chosen curly maple board had defects preventing full width use.


• Cutting method: Used jigsaw and bandsaw to cut out necessary parts.

Flattening the Wood

• First experience with figured wood: Jointer and planer used to flatten boards.


• Jointer: Helical head provided a flawless surface with no tearout.


• Planer: Straight knife cutter head required shallow cuts to reduce tearout.

Resawing and Sizing

• Stock thickness: Started with heavy 4/4 stock, resawed to 3/8” thick.


• Cutting box sides: Used spacer blocks at miter saw for four box sides.


• Grain continuity: Discussions on starting and stopping grain; explored continuous grain method.

Trimming the Sides

• Trimming dimensions: Sides looked tall, trimmed on the table saw.


• Bevel cuts: Tilted blade to 45 degrees for testing joint alignment.


• Stop block: Used to avoid removing length; just beveled edges.

Preparing Panels

• Panel material: Same material for top and bottom with a glued rabbet.


• Veneer application: Made veneer and glued onto plywood for stability.


• Plywood specification: Used 5mm hardwood plywood with layers perpendicular to the veneer.

Rabbet Cutting

• Setting up the saw: Adjusted saw blade height with the dried panel.


• Rabbet sizing: Cut rabbet for top and bottom pieces with 1/16″ margin to sides.

Glue Application and Squeeze out Prevention

• Preventing glue stain: Taped off inside faces of the box.


• Using tape as clamp: Rolled boxes to apply glue.


• Glue application: Used a cheap paintbrush for even application.

Panel Fitting

• Tuning panel fit: Panels sized for top and bottom rabbets; a loose fit preferred.


• Precision cutting: Saw blade set for symmetrical rabbet around perimeter of panels.

Inlaying Walnut

• Wood selection: Chose walnut for contrasting inlay.


• Material preparation: Cut strips to 1/4” x 1/4” square.


• Extra pieces: Always cut additional pieces for potential mistakes.

Fitting Inlay

• Direction of work: Worked clockwise around the box; utilized shooting board for accuracy.


• Trim fitting: Cut rough angle; refined to accurate 45 degrees for perfect miters.


• Taping method: Used blue tape to hold pieces in place while fitting next pieces.

Gluing Inlay

• Inlay installation: Lifted inlay pieces with tape, applied glue, and repositioned.


• Flush trimming: Used hand planes to trim inlay flush with the box, preventing tearout.

Separating the Lid

• Joining method: Set blade to not cut all the way through for safety.


• Separation technique: Used a sharp utility knife to break pieces apart.

Hinge Installation

• Layout process: Marked hinge positions with a marking knife and made them pronounced with a chisel.


• Routing mortise: Set router to half-depth of hinge for mortising.


• Screw hole preparation: Marked offset slightly inside to ensure tight seating.

Final Touches

• Sanding: Light sanding to remove saw marks completed.


• Finishing: Applied shellac, with plans to add additional features in future.