Boxes to Build (Preview)

Boxes to Build Sturdy & Stylish Projects to Organize Your Home & Shop

From the Editors of

Boxes to Build Sturdy & Stylish Projects to Organize Your Home & Shop

From the Editors of

Page 126

CONTENTS

3. CABINETS Page 14

1. SMALL BOXES Jasmine Jewelry Box

7

Shaker Wall Cupboard

101

Roy Underhill's Nail Cabinet

104

Illusion Cabinet

111

Pleasant Hill Classic Cupboard

118

Inlaid (Bible?) Box

14

Contemporary Cabinet

126

Kreneov-Style Memories Box

23

Medicine Cabinet

134

Rediscover a Shaker Classic

29

Eight Common Hinges

141

Japanese Sliding-Lid Box

36

Stacking Tool Caddy

41

Tools and Supplies

149

Old Plane Birdhouse

47

Contributors

149

Index

150

2. CHESTS & STORAGE Country Tool & Toy Chest

51

Stacking Bookcases

54

Pleasant Hill Firewood Box

57

Six-Board Chest

60

A Simple Sea Chest

66

Danish Modern Campaign Chest

72

Shaker Blanket Chest

81

Traveling Toolbox

88

Greene & Greene-Style Blanket Chest 93

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SMALL BOXES SMALL BOXES MAKE FANTASTIC GIFTS, and are a great way to utilize shorter pieces of stock you may have been saving up in your shop. Everyone can use a little more organization—the clever boxes showcased here will become dedicated spots for whatever you need, be it a caddy for tools or arts and crafts materials, or a delicate receptacle for jewelry, trinkets, spare change, or even photographs and keepsakes. And let’s not forget that so many woodworking pieces begin with the humble shape of an enclosed box, including birdhouses. The projects feature decorative and practical details like dovetail joinery, bent wood, sliding lids, inlay, and more.

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Small Boxes: ■

Ashtastic. This ash, finger-jointed jewelry box is simple to build with just a few tools: A bandsaw, chisel, handplane, and router are all that’s required.

JASMINE JEWELRY BOX Simple tools, techniques & joinery deliver elegant results.

BY GARY ROGOWSKI

I

t’s the stuff of arguments: Which tools in the shop are really the most important for joinery? It’s almost like arguing the top movie or the best shortstop of all time. There is no one answer that satisfies everyone (although “The Maltese Falcon” and “Ernie Banks” should). Were you to ask me, my answers would be quick but not absolute. Give me three tools—a bandsaw, a chisel, and a router—and I can build just about anything. This jewelry box project shows how versatile these tools are.

Divisible by three. To lay out your finger joints, place a ruler at the edge of your board, then angle it to the opposite edge until you have a measurement easily divisible by three—and ensure the center slot is a hair wider than the chisel you wish to use.

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INLAID (BIBLE?) BOX Scholars question whether these boxes actually held the family’s Bible; regardless, this Pennsylvania-designed box deserves high praise.

BY GLEN D. HUEY

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BOXES TO BUILD

F

rom the minute I brought this lidded box into the Popular Woodworking office, debate began. I called it a Bible box, but some wondered where that term originated.

Is it a name coined by those looking to build an interest in these boxes so they could sell them for a profit? Or is that term what the original owner used in 1730?

You can call it a Bible box, a lidded box, or whatever you like. I’m going to call it a great project that is an introduction to, or a chance to practice and improve upon, many woodworking techniques, from lathe work to shopmade herringbone inlay to half-blind dovetails. And it’s a project that I’ve had on my “to build” list for many years.

Built with love. The wild apple top was the starting point for this “memories box” I made for my wife. The rest of the box is made of Swiss pear.

KRENOV-STYLE MEMORIES BOX Wood is the starting point of inspiration for these boxes infused with the past.

BY TED BROWN

I

n my mind, this article goes to the root of why we work wood. It is about the philosophy of creating things in wood and the approach, more so than the technical application of skill. Back in 1993, I spent nine months studying a way of working under James Krenov at the College of the Redwoods in Fort Bragg, Calif. Yes, I learned technical things there, but more important is that Jim inspired us to think, to be sensitive in our choices, and to do the very best we could in the execution.

If you have read Jim’s books, you will immediately grasp the fact that his way of working was significantly different from the rest. Jim was excited by the wood itself, and how he could gently massage the material to create a piece with a natural look, with a feeling. I once heard him say something along the lines of, “When you look at a piece of fine furniture, you are not just looking at the piece, but a significant portion of the maker’s life.”

Surprise. Inside the larger box is the surprise of a smaller one.

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LEAD PHOTO BY AL PARRISH; STEP PHOTOS BY THE AUTHOR; ILLUSTRATIONS BY DAN PESSELL FROM THE AUTHOR’S DRAWINGS

REDISCOVER A SHAKER CLASSIC A rim and box in contrasting species make an elegant eye-catcher.

BY JOHN WILSON

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JAPANESE SLIDING-LID BOX This clever and simple piece is great for storing tools, toys, or a kimono.

BY CHRISTOPHER SCHWARZ

36

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hile picking though a table of vintage Japanese tools for sale in 2013, I spotted a sliding-lid box under the vendor’s table; it was blackened by age, soot, and rust.

Despite its scars, however, the box was still graceful and functional.

The owner, a Japanese carpenter, wouldn’t part with it. But he let me measure and photograph the piece both inside and out so I could make a respectable version for myself.

The carpenter said it was a toolbox, and it would indeed fit a small kit of tools. But other experts in Japanese furniture said it was more likely a

STACKING TOOL CADDY A simple-to-build tote, perfect for tool and supplies transport.

B Y C H A D S TA N T O N

I

designed this stacking tool caddy to hold small parts and a few tools. It comprises three tool trays that stack and interlock together to form a single unit that can be carried wherever needed. Best of all, it stores my screws, nails, and small tools so they’re all right at hand. It’s also handy for transporting

other items: sewing supplies, fishing tackle, and whatever else you can think up.

The trays are joined with half-laps secured by dowels. The dowels not only add strength but also add a nice decorative detail to the project. To lock the trays together, the main handle pivots,

allowing access to the individual trays.

A tongue depressor acts as a simple spring latch.

TRAYS FIRST The sides for each tray are 1⁄2" x 31⁄2" poplar (dimensional 1⁄2" x 4 lumber from the big box store). To begin the conBOXES TO BUILD

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OLD PLANE BIRDHOUSE You’d be surprised how many woodworking projects start with building a box.

I

’ve never been a fan of birdhouses.

Why welcome something to your yard that wants to poo on your head?

Yet, inspiration works in weird ways. While visiting Maine, I saw an enormous birdhouse that looked like a jointer plane hanging outside Liberty Tool, an ironmonger. I just had to have one to hang above my shop door.

BY CHRISTOPHER SCHWARZ

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2

CHESTS & STORAGE THESE LARGER BOXES FIT THE BILL when some serious storage capacity is required. Books, firewood, toys, tools, blankets—what do you have that needs to be put away? Choose the aesthetic of your choice and dive in. From a simple country style brightened with paint to the canted angles of a sea chest, or perhaps the elegant simplicity of the Shaker style or the through joints and exposed ebony of Greene & Greene, there is a design here to complement any home decor. The sturdy pieces within are robust enough to withstand decades of use at the foot of your bed or flanking your front door.

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BOXES TO BUILD

COUNTRY TOOL & TOY CHEST Nails, glue, and a nice long day in the shop are all it takes.

T

his rustic hinged-lid box is a design traditionally used as a basic tool chest, but I thought a scaled-down version would make a great chest for stashing toys (with the addition of a safety hinge) or extra grocery bags in the kitchen. It is adapted from a chest shown in John A. and Joyce C. Nelson’s The Big Book of Weekend Woodworking.

B Y M E G A N F I T Z PAT R I C K

A TRIP TO THE HOME CENTER A trip to the home center is the beginning of this country tool and toy chest project, and there I assessed every #2 pine 1x12 in stock. Because I’d decided BOXES TO BUILD

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STACKING BOOKCASES Make boxes to fit your books and your space.

BY ROBERT W. LANG

T

he typical bookcase is a good example of poor design. We make them that way because that’s the way we’ve always made them; almost every plan you see is 12" deep, yet few books require that much space.

Most bookcases are heavy and a pain to move. These stacking bookcases solve those problems, and won’t take long to build.

Before you begin, assess your library. The three sizes shown here are based on common lumber sizes, and typical sizes of books. If you stay with standard 1x lumber, you won’t be able to change the depth, but you can change the height and width.

An inch or two higher than your tallest book is a good inside height, but don’t go too wide; beyond 36" and the shelves may begin to sag. Also consider how the parts of the sizes you are planning will fit the available lengths of material; an inch or so of adjustment may save you from buying another board.

GET READY TO RABBET The individual boxes could be just glued and nailed together, but the rabbet joints shown here will be stronger, and the boxes will be easier to assemble. I used a 3⁄8"-wide rabbeting bit that uses a ball bearing below the cutter as a guide.

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Made to order. Fit the cases to your books to avoid wasting space, lower your material costs, and make moving easy.

Repurposed. While originally designed to be used to hold firewood and kindling, this Shaker piece also can be pressed into service as a recycling bin.

PLEASANT HILL FIREWOOD BOX A classic Shaker design with enough curves to make it interesting.

BY CHRISTOPHER SCHWARZ

T

he buildings at the Shaker Village in Pleasant Hill, Ky., are filled with handy firewood boxes.

After a few visits to the colony, I concluded that this example is the best one.

Tucked into a room in the Centre Family Dwelling, this firewood box represents what I like about the Western Shaker furniture styles. This box has a few graceful and unexpected curves, yet it still looks decidedly Shaker.

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Variations on a form. The blue chest is the one I built for this article—but let your wood and aesthetics dictate your build.

(The yellow chest is by Timothy Henriksen; the green chest is

by Ty Black.)

SIX-BOARD CHEST Use two planks, two days, and two piles of nails to make this age-old form.

BY CHRISTOPHER SCHWARZ

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BOXES TO BUILD

While the angled panels make this chest look difficult to build, the construction is actually quite simple. It’s a great introduction to angled work for the beginning woodworker.

A SIMPLE SEA CHEST Whether you’re a polished skipper or a certified landlubber, you’ll find many reasons to build this canted-side sea chest.

BY GLEN HUEY

66

BOXES TO BUILD

I

f you were a sailor who sailed deep waters prior to 1870, you packed your belongings into a sea chest. (Coastal sailors, those who returned to port often, used a sea bag.) Sea chests— banned by the United States Navy in 1870 due to the lack of space for each sailor to have his own chest—are simply six-board chests.

Designs range from straight-sided chests, to those that are canted or angled on the front, to examples with both the front and back canted.

Why are the sides angled? That was to help protect sailor’s shins from knocking the lid as the ship rocked with the swells of the water.

While most sea chests feature dovetailed corners, we’ve simplified the construction of this example and maintained the design to build a chest with basic joinery.

SET SAIL ON THE PROJECT To begin construction, mill the four case panels—both ends, the front, and

DANISH MODERN CAMPAIGN CHEST Built to move (and to last), this piece blends classic proportions and clean lines.

BY CHRISTOPHER SCHWARZ

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BOXES TO BUILD

SHAKER BLANKET CHEST This piece from White Water Village shows a Southern influence.

B Y M E G A N F I T Z PAT R I C K

Store your stuff in style. This blanket chest is based on a 19th-century example from a southwest Ohio Shaker community, but the dovetail layout shows the influence of Southern furniture. In typical fashion, the till lid doubles as a chest lid stay.

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TRAVELING TOOLBOX Bodger and blacksmith Don Weber shows how to effectively combine power and hand-tool techniques to build a simple and sturdy toolbox.

BY DON WEBER

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GREENE & GREENE-STYLE BLANKET CHEST A simple approach to a sublime design.

B Y M A R C S PA G N U O L O

I

’ve been enamored of Greene & Greene furniture since my early days of woodworking, well before I possessed the skills to produce such a piece. Since that time, this style has become a regular part of my woodworking vocabulary, and I enjoy making reproductions and interpretations of classic Greene & Greene designs. This blanket chest is a re-imagining of an

original piece designed by the Greene brothers (Charles and Henry) for the Thorsen House in Berkeley, Calif.

My wood of choice for this project was khaya, sometimes referred to as African mahogany. The original Thorsen House box was made from red oak—so don’t hesitate to use a domestic species if exotic woods don’t suit your taste or budget.

The bottom of the blanket chest is made from 3⁄4" plywood, and you can save a bunch of cash by using a domestic-veneered species instead of seeking out mahogany-faced stock. The ebony trim comes from a 2" x 2" x 12" turning blank, which should provide enough ebony for several projects.

The case panels are glued up from several narrower boards. Take care to BOXES TO BUILD

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3

CABINETS IF YOU’VE HAD ENOUGH OF LIDS, get ready for doors! These mostly wall-hung cabinets are perfect for curios, toiletries, hardware, spices, or whatever else you can think up. Whether you need a passel of drawers, a column of shelves, or just a small cupboard, there’s a project here for you. Highlight a beautifully grained door panel, go the more affordable route with a painted finish, or mount a mirror. And don’t forget the astonishing variety of hinges available—from European to piano to butt hinges, there is a design to fit your particular project that will also give it some flair.

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BOXES TO BUILD

SHAKER WALL CUPBOARD A classic form from the New Lebanon Shaker community is easy to build in a few hours.

Simply red. The original cabinet is cherry with a varnish finish. It looks good in a variety of woods, including this poplar version with a red wash.

BY CHRISTOPHER SCHWARZ

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On the set. Roy Underhill’s nail cabinet is a converted crate. The cabinet has seen a lot of use and has held up pretty well.

ROY UNDERHILL’S NAIL CABINET It’s a crate. It’s a cabinet. It’s useful shop furniture.

BY CHRISTOPHER SCHWARZ

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BOXES TO BUILD

ILLUSION CABINET Stylish legs and a dapper door dress up a simple case piece—and help to deceive the eye.

BY GARY ROGOWSKI

T

his design is inspired by a taper, but I needed to establish the right proportions to flesh the idea out. In much of my design work, I hover around the safe ground of a 3:5 or a 2:3 proportion in the neighborhood of Golden proportions.

For this cabinet, I thought if I were to make the eye search a bit, then a more distinct ratio was in order.

Throughout the design, from the overall dimensions of the case to the size of the parts of the door, everything was held as close as possible to 1:2. This made for noticeable changes in shapes both in the overall form of the piece and in its members.

SIMPLIFIED CONSTRUCTION The cabinet appears to be frame-andpanel construction with the legs proud of the side panels. But the sides are solid with the legs simply glued on.

To yield 13" in width, I assembled the sides from two mahogany boards. I finished planing and sanding both panels then cut them to final length before gluing on the 1⁄16"-overlong legs, which are also mahogany. It’s a bit easier to manage cleanup this way.

I milled the legs, cut the taper on the bandsaw, and cleaned the faces on BOXES TO BUILD

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PLEASANT HILL CLASSIC CUPBOARD Common wood from a common source creates an uncommon beauty.

BY KERRY PIERCE

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CONTEMPORARY CABINET The inspiration for this simple build hangs on a live-edge piece of walnut.

B Y M E G A N F I T Z PAT R I C K

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MEDICINE CABINET A slick technique makes the divided-light door a snap.

B Y M E G A N F I T Z PAT R I C K

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EIGHT COMMON HINGES Every door needs a hinge—find out which hinges to use, the advantages of each type, and how to install them.

W

herever there’s a door, there must be hinges—and just as there’s a galaxy of door types, there is a variety of hinges and modes of installation. Even when we narrow the field to those used in furniture and built-ins (as distinct from entry doors or gates designed for cattle), the options are many. Here, we’ll describe the uses and installation of several common varieties.

BY NANCY HILLER

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Shaker Village 30, 57, 82, 87, 119 Shaker Wall Cupboard 101–103 shellac 13, 22, 27, 28, 53, 56, 71, 80, 105, 110, 116, 117, 133 scenting 117 shim 8, 9, 114, 116, 147, 148 shiplapped joints 105, 136 Six-Board Chest 60–65 sizing 55 SketchUp 135 sliding-lid box 36 small boxes 6–48 spring joint 10, 11 Stacking Bookcases 54–56 Stacking Tool Caddy 41–47 stiles 25, 26, 102, 105, 107, 108, 110, 115, 116, 117, 120, 123, 124, 125, 128, 130, 146 strap hinge 52, 53, 69, 71 surface-mounted hinges 142

T taiko byo 37, 149 tail board 15, 17, 27, 85, 86, 105 template 12, 35, 58, 59, 74, 75, 94, 95, 96, 98, 112, 114, 115, 133 tenon 10, 11, 16, 17, 18, 25, 26, 74, 80, 83, 84, 86, 95, 112, 113, 115, 124, 125, 131, 135 The Woodwright’s Shop 105 till lid 81, 83, 84, 85, 86 toolbox 88 tool caddy 41 tool chest 51 tools and supplies 149 tote 41 toy chest 51 Traveling Toolbox 88–92 trays 41

U Underhill, Roy 104, 105, 106, 107, 108, 109, 110

Text and photographs © 2021 by Cedar Lane Press All rights reserved. Excepting patterns, no part of this book may be reproduced or transmitted in any form or by any means, electric or mechanical, including photocopying, recording, or by any information storage and retrieval system, without written permission from the Publisher.

Readers may make copies of patterns for personal use. The patterns themselves, however, are not to be duplicated for resale or distribution under any circumstances. Any such copying is a violation of copyright law. Previously published in Popular Woodworking.

Publisher: Paul McGahren Editorial Director: Kerri Grzybicki Design & Layout: Clare Finney Cedar Lane Press PO Box 5424 Lancaster, PA 17606-5424 Paperback ISBN: 978-1-950934-73-7 ePub ISBN: 978-1-950934-74-4 Library of Congress Control Number: 2021945060 Printed in the United States of America 10 9 8 7 6 5 4 3 2 1

Note: The following list contains names used in Boxes to Build that may be registered with the United States Copyright Office: Ball & Ball; Briwax; Brusso; Clapham’s Beeswax Products Ltd.; College of the Redwoods; Festool (DOMINO); General Finishes; Highland Woodworking; Horton Brasses, Inc.; kaDON; Liberty Tool; Loctite; Marples; Ohio Blue Tip Matches ; Olympic; PBS (The Woodwright’s Shop ); RustOleum (Watco); Scotch-Brite; Shaker Design; Simple Gifts, 25 Authentic Shaker Craft Projects; Stanley; The Big Book of Weekend Woodworking; The Shaker Legacy; Tremont Nail Co.; Tupperware; Van Dyke’s Restorers; Watco; Whitechapel Ltd.

The information in this book is given in good faith; however, no warranty is given, nor are results

V

guaranteed. Woodworking is inherently dangerous. Your safety is your responsibility. Neither

varnish 35, 46, 87, 92, 101

Cedar Lane Press nor the author assume any responsibility for any injuries or accidents.

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To learn more about Cedar Lane Press books, or to find a retailer near you, email

White Water Village 81

Info@CedarLanePress.com or visit us at www.CedarLanePress.com.

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CRAFTS & HOBBIES: WOODWORKING

HARDWORKING BOXES TO GET ORGANIZED IN STYLE

B

oxes have always been a popular project for woodworkers. They can be small and quick to build, or large with enjoyable challenges in joinery and design. They also make great gifts.

But sometimes, a box is needed to simply organize or protect your stuff. You don’t need a delicate, precious keepsake; you want a box, chest, or cabinet that’s sturdy, good looking, and designed to complete the task, whether it’s holding your tools, winter blankets, or a family Bible.

Compiled from the pages of Popular Woodworking, Boxes to Build features twenty-two hardworking, useful projects that you’ll want to build. Featuring designs and how-to from some of today’s top woodworkers, Boxes to Build is a woodworking book that’s fueled by function, but doesn’t skimp on form. Ideal for all skill levels, these boxes will quickly—and proudly—be put to use making your life more organized, less complicated, and very stylish.

978-1-950934-73-7 $24.95 US