Boxes come in all shapes, sizes, and materials. Making a box is a great way to learn the basics of working with wood or metal. These projects are easy to complete and can familiarize you with the machinery and tools related to the job. Follow this guide to make simple boxes that have a multitude of uses.
Method 1 of 2: Make a Metal Box
Step 1. Get sheet metal
You will need a type of metal that is thick enough for your box to be sturdy, but at the same time delegated so that it can be bent. Pipe metal is a good material. Start with a rectangular piece.
Step 2. Measure the cuts and folds
Draw a line on your sheet metal to designate the location of the cuts and folds. You will need to fold all four sides to create the walls of the box, so measure four equal lines parallel to the edges. These lines will mark where the walls will fold.
- You will also need to fold towards the top of each wall to hide the sharp edges. Draw a parallel line a short distance below each of the edges.
- Mark equal squares in each corner of the rectangle. This square may already have been formed thanks to the fold lines you drew earlier. You will need to cut this square to create flaps that become the sides of the box.
Step 3. Cut out the squares
Clamp the sheet metal to your workbench so it won't shake or vibrate during the cutting process. Use a jigsaw or other hacksaw and work slowly to make sure you cut straight lines.
Step 4. Fold the top edges
Once all the squares are cut out, you will be left with all four flaps. You will need to fold the edges of these flaps to make smooth edges on the top of the box. Place the first edge on a folder. Make sure it matches the line you measured earlier. Fold the edge 90 °, which will create an edge.
- If you don't have a folder, lay the veneer on the edge of a table and lay a piece of wood on top. Clamp the wood to the table as tightly as possible. The piece of wood will act as the prop for the folder, allowing you to bend the metal by hand or with a mallet.
Step 5. Hammer the edge down
Continue the folding process by hammering the edges down so they are flush with the flap. Repeat this process for all four flaps.
Step 6. Fold the walls up
Now that the tops of the walls are finished, it's time to start lifting them, lining up the crease line you measured earlier. Bend the wall up at a 90 ° angle. Repeat this process for each wall.
Step 7. Secure the corners
At this point, your box should look almost complete. All four walls should face up and the top edges should be folded. Now you will need to secure the corners with smaller pieces of metal.
- Measure the height of the box. Cut four strips of metal, each long enough to reach from the bottom to the top of the box and wide enough so that you can fold them in half and secure them (usually about 2.5 cm or 1 inch). inch on each side, therefore it should be about 5 to 7 cm or 2-3 inches in overall width).
- Lay each strip lengthwise on the folder with half in and half out. Bend each one at a 90 ° angle
Step 8. Place the tie sheets in the corners
Once you have folded them, place the tie sheets at each corner of the box and punch holes through the tie sheet and through the box. Drill two holes on each side of the fold and insert rivets into each of them. Use a ball hammer or rivet gun to set them.
- Once you set all the rivets, the box is complete.
Method 2 of 2: Make a Wooden Box
Step 1. Measure the wood
You will need to make sure that all the walls are the same height. Opposite walls must be the same length. You will also need a base piece that will fit inside the finished box.
Step 2. Prepare the corners
At the ends of each of the pieces that will be the walls, cut at an angle of 45 ° from the inside of each edge. These 45 ° angles will meet and form aligned edges without showing any indication of the grain.
Use a miter box to create exact angles. This will result in continuous seams. Make sure to modify the overall length of the wall pieces when cutting at a 45 ° angle
Step 3. Attach a long piece of packing tape
Gather each wall end-to-end on the tape so that the edges touch. The pieces should be arranged in a way that looks as if the walls of the box are "unrolled."
Step 4. Glue the bottom to one of the walls
Let the glue dry and apply constant pressure with the help of a clamp. Once the glue has dried, apply it to the rest of the exposed edges of the base.
Step 5. Apply glue to the corners
Apply strong wood glue to the 45 ° corners. File the edges before applying the glue to improve the grip of the seams.
Step 6. Roll up the walls
With the packing tape still in place, roll up the walls so that the 45 ° angles fit together. If you took the measurements correctly, the bottom of the box should fit perfectly against the walls. Hold the sides firmly and let the glue dry.
Step 7. Add a lid
You can create a simple lid by measuring a piece of wood that extends just past the edge of the box. Glue small pieces of wood around the edge of the new piece to prevent the lid from falling off.
Step 8. Decorate the box
You can sand the edges if you would like them to be more curved. Paint the box according to your taste.