See page 2 for materials list, diagrams and rest of instructions
This simple, triple-decker project began with a need for spare seating on my deck. I wanted something that could stack out of the way between uses, and which was sized to suit both little and big people. This project was designed with simple joinery and low-cost materials, so it would be fun, easy and cheap.
You probably have more than enough scrap in your workshop to build these boxes, but you can also use finer materials to suit your style-whatever reflects your personal tastes.
Choose your wood
The construction of this project is simple. First, choose your stock. Since I would be painting the wood, I wasn't concerned with appearance. I decided to laminate two thicknesses of 3/4" spruce plywood. To keep things inexpensive, this was the best option. You could also edge-glue 2-by lumber if you wish.
Take two and a half 3/4"-thick sheets of 4x8 plywood and cut them to 22" wide on your tablesaw. You should end up with six pieces of wood, 96" long each. All of the boxes have the same front-to-back width; only the height changes. When you've finished these first cuts, glue and clamp two pieces of ply together in 96" lengths. This takes a lot of glue, so consider using a paint roller to spread it smoothly.
Even when the clamps are in place, you may still have trouble getting the middle area of each double sheet tight. After all, the clamps can only go around the edges. Solve this problem by drawing the middle areas together temporarily with #8 x 1" wood screws. Orient the screw holes left behind in the middle of the boxes so they won't be seen.
Box it up
When the glue is dry, remove the clamps and run the pieces through your tablesaw again to remove irregularities along the edges, which will trim down your ply to a final width of 22" after adding 1/4"-thick edging along each edge. Cut the parts you need for the large box, then glue and clamp the components together. The sizes in the materials list are for boxes assembled with butt joints. Add three inches to the length of the sides if you plan to create mitred corners.
0 Comment