How to Build a Strong Wooden Box

A box made with cut joints is much stronger.

Wooden boxes make sturdy storage containers. A wooden box can be made even stronger by using a box joint. A box joint provides more surface area of the wood to bond together, creating a stronger joint. Boxes made using this woodworking technique can withstand rough handling and are often used for storage and freight containers. If you have a table saw, you can make box joints in your home workshop.

Things You'll Need

• 3/4-inch by 4-inch by 16-inch pine board
• Table saw with 1/4-inch dado set
• 1/4-inch by 1/4-inch by 6-inch wood strips (2)
• 2 wood screws
• Screwdriver
• 1-inch by 2 1/4-inch by 6-inch oak boards
• Wood glue
• Bar clamps
• Damp rag
• 6-inch by 6-inch oak boards (2)
• Finish nails
• Hammer
• 120-grit sandpaper
• Wood finish
• 2 hinges, with screws
• latch, with screws
• 4 felt pads

Instructions

How to Build a Strong Wooden Box

1. Set up the table saw to make a 1/4-inch deep cut. Make a 1/4-inch by 1/4-inch cut approximately one inch from the edge of a 4-inch by16-inch pine board. This is the backer board. It will be used as part of a jig to make the box joints.

2. Place one 1/4-inch by 6-inch wood strip into the cut. Place the backer board with strip on the table of the table saw. Place another 1/4-inch by 6-inch wood strip between the strip in the backer board and the blade of the saw. This is a spacer. Fasten the backer board to the miter gauge by putting a wood screw through each hole in the miter gauge and screwing them into the backer board with a screwdriver. The jig is now complete and ready to use.

3. Place one end of a 2 1/4-inch by 6-inch oak board on the table saw so that the edge of the board is tight against the strip in the backer board. Run the board through the table saw to make the first cut. Remove the board from the table saw after the cut is complete. Place the cut over the strip in the backer board. Make another cut. Continue making cuts and placing the cut over the strip in the backer until you have reached the end of the board. Flip the board over and repeat the same procedure. Follow the same procedure with a second board. These are the sides of the box.

4. Place one end of a 2 1/4-inch by 6-inch oak board on the table saw. Set the second strip between the edge of the board and the strip that is in the backer board. This will make the cuts in this board offset from the other boards. Place the cut in the strip that is in the backer board and proceed until you reach the edge of the board. Flip the board over and repeat the same procedure. Follow the same procedure with a second board. These are the ends of the box.

5. Apply wood glue to all the joints of the ends and sides of the box. Put the sides and ends together to form a box. Clamp the box together using bar clamps. Wipe off any excess glue with a damp rag. Allow the glue to dry according to the instructions provided on the glue container. Remove the bar clamps.

6. Place one 6-inch by 6-inch oak board on top of the box assembly. This is the bottom of the box. Apply a bead of wood glue around the edges of the box. Fasten the bottom to the box assembly using finish nails and a hammer. Space the nails evenly every two inches. Wipe off any excess glue with a damp rag.

7. Sand the entire box using 120-grit sandpaper. Apply a wood finish of your choice. Allow the finish to dry according to the instructions on the wood finish container.

8. Place the final 6-inch by 6-inch oak board on top of the box assembly. This is the box lid. Align hinges approximately one inch from the edges of one side of the lid. Fasten the hinges to the under side of the lid and the inside of one box side using screws and a screwdriver. On the side opposite the hinges align the latch in the center of the lid. Fasten the latch to the lid and inside wall of the box using screws and a screwdriver. Place four felt pads on on the corners of the bottom of the box.

Tips & Warnings

• Make the sides and ends out of different kinds of wood in order to accentuate the beauty of the box joints.

• Wear eye protection when working with wood.

References

• Sawdust Making: Box Joint Jig
• Inside Woodworking: Box Joint Jig
• New Woodworker: Box Joint Jig

Resources

• Read this Article in Spanish
• Woodworking Corner: How to Build a Wood Box