How to Make a Wooden Trunk

Make decorative feet and apply metal cladding to enhance the look of a truck.

Wooden trunks have a long history and were once used as commonly as suitcases are used today. With a few tools, they can easily be constructed. Such trunks are used to store items of any kind and can be tailor-made to fit items of almost any size. Trunks can be made in any style whether historical or purely functional. A rack, for example can be broken down and all the pieces stored in one trunk. A simple plywood trunk would easily provide this and be fitted with padding and strapping to hold the pieces steady inside.

Things You'll Need

• 1-inch plywood
• Saw
• Jigsaw (optional)
• Hinges
• Latch
• Wood screws (2-inch)
• Measuring tape

Instructions

1. Gather your materials and tools. Write down the sizes of the pieces of plywood you will need to complete the trunk. Write down the measurements for the sides, front and back, bottom and top of the trunk. Mark out the pieces on the plywood sheet with a ruler and pencil. Take the width of the plywood into account to get the exact size for the trunk. If the front piece of the trunk is 2 feet long, expect it to be 1 inch longer when finished, as each side piece will add another 1/2 inch to the overall length.

2. Saw the pieces you need out of the plywood sheet(s). Cut the side panels so that they are the exact width and height of the trunk. Cut the bottom, front and back walls of the trunk the same size, and 1 inch shorter than the intended overall length of the trunk. The top, which is also the lid, should be flush with all sides as well as the front and back of the trunk.

3. Sand all the edges of the pieces with sandpaper and dry-fit them to check that they are cut correctly. Use clamps to secure the floor piece on the table. Hold one side-piece in place against the bottom edge of the floor-piece lying flat on the table. Use screws every 2 inches to connect it to the bottom. Repeat the process on the other side.

4. Place the back portion on top of the bottom piece along the back edge, snug between the two side. Use more screws to fasten the sides to the back. Turn the screws from the side pieces into the back to secure it into place. Repeat this step to fasten the front piece for the trunk. You should now have a solid box with an open top.

5. Place the top piece on the box to make the lid. Use screws to attach the hinges on the back. Attach them near both ends of the top piece and fasten the other half of the hinges to the back piece. Attach a latch at the center in front so that you can lock the trunk. The lid should be flush on the box on all sides.

6. Paint or varnish the trunk to protect the wood from moisture. Attach any customized padding and straps to the inside of the trunk to secure particular items. Attach handles or cut out holes with a jigsaw on either side of the trunk to make lifting easier if desired. Use 1-inch screws to attach them so they do not protrude inside the trunk.

Tips & Warnings

• Wear protective equipment when cutting and sanding.

References

• Lee's Wood Projects: How to Build a Wood Storage Chest