EASY STEPS TO MAKE YOUR PENCIL BOX

Gather your supplies

• 89 x 19mm x 1.8m dressed pine

• 897 x 600 x 7mm plywood

Components

Sides 89 x 19 x 300mm dressed pine (3)

Front 71 x 19 x 300mm dressed pine (1)

Handle 18 x 19 x 300mm dressed pine (1)

Lid, Bo om 270 x 270 x 7mm plywood (2)

You’ll also need

Trimmer fi‰ed with a 6mm straight cut bit; mitre saw; masking tape; PVA glue; ratchet strap; measuring tape; 20mm nails; hammer; sandpaper; undercoat; enamel paint; clear varnish; painting equipment

Here’s how

STEP 1 To make a channel in the pine for lid to slide into, use your trimmer with guide a‰ached to cut a 5mm deep channel along the pine, 10mm from 1 edge. Adjust guide to widen the channel by 1.5mm to allow the plywood to fit and slide easily. Make another pass.

STEP 2 On opposite side of pine, use trimmer and the same process for a 7.5mm wide rebate along edge for the bo‰om to fit into.

STEP 3 Use mitre saw to cut out the components. Cut a 45™ angle on each end to form mitred corners. Take care to make sure they are exactly the same length so joins are nice and tight. Cut front and handle with the rebate along 1 long edge.

STEP 4 Lay out sides and front face up on the bench, end to end, with rebated edges all on the same side. Place pieces of masking tape across joins to hold them together. Hang

2 pieces of masking tape off one end piece.

STEP 5 Carefully turn over and spread PVA glue along the joins. Li‚ the whole lot on edge and wrap them around to form the box. Use tape hanging off the end to hold the last join together.

STEP 6 Make joins in corners tight and align edges of box pieces. Remove excess glue, including from inside the channel. Place a ratchet strap around the box and tighten to pull joins together. Measure diagonals to check box is square and adjust if necessary. Leave for 4 hours to dry before removing straps.

STEP 7 Spread glue in rebate on edge of box, sit bo‰om in and nail.

STEP 8 Slide lid into channels to check for fit. Sand edges to make it slide more easily if required. Glue handle to one side of lid and then insert into box before glue dries to ensure it shuts neatly. Carefully remove and leave to dry.

STEP 9 Sand box and lid to

DIY TIP

• Don’t have a trimmer? Use your circular saw set to cut 5mm deep to remove the timber for the channel, then clean it up using a sharp chisel. remove excess glue and smooth timber. Remove dust. Undercoat and paint in your choice of colours. Allow to dry a‚er each coat. Finish by applying a clear varnish to protect the raw timber. Let dry.

STEP 10 Cut dividers for inside box out of plywood to suit the dimensions of your storage spaces . Undercoat, paint and let dry. Spread a thin bead of glue along all edges but the top and sit dividers inside the box. Allow to dry.

STEP 1