Articles By Syndicated Columnist
Dan Thomas
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Improvement Inside And Out
Building A
Toy Box
When I build this toy box the parents just love it. It acts
as a
double-duty storage box and chalk board where the kids can go wild but in a
paperless way. Chalkboard paint makes it a snap to turn any surface into a
doodling board.Please make a note the toy/play box is not a free standing unit. You will
need to place it by a fence, wall or structure.
Begin by cutting the pieces that will make up the body of
the box from two
4' x 8'sheets of ¾" plywood. One 48" x 68" back; one
18-1/2" x 48" base; one 19-1/4" x 48" face; two
18-1/2" x 19-1/4" sides. To make a hinge support cut a cedar 2"
x 4" to a length of 46".
For the box you will need, carpenter's glue, and 1-1/2" #8 woodscrews.
Prime and Paint the bun feet with a light sanding between coats; then, to
install them, drill a ¼" centering hole 2-1/2" from the front or
back and side in each corner. Attach from inside the box with three
1-1/2" woodscrews.
Prime the exterior of the box; then paint the face and upper panel with
Rust-oleum black chalkboard paint; sand lightly between coats.
To make the cedar surround for the upper panel, rip three 8' cedar 2"
x 4" to 2". On the cut face dado a ¾" channel 1-3/8"
deep, 5/8" from the 2" front edge. Use a trim router with a ¼"
round-over bit to finish the front edge. Next cut the two side caps at
68" and remove the 5/8" tongue from the bottom 19-1/4" of each
cap where it fits along the edge of the box.
With the third piece cut the top cap at 69-1/4" and remove the front
and back tongues from 2" on either end to fit between two side rails and
cap the corners. Glue and pin the surround using 1-1/4" 18-gauge brad
nails
To make the cap for the top edge of the box rip an 8' 2 x 4 to 2-1/2"
and center a 1" dado ¾" deep. Notch the side caps to fit over the 2
x 4 hinge support and mitre the corners to fit the front cap. Glue and pin the
cap using 1-1/4" 18-gauge brad nails. Next rip a 2 x 4 from 1-1/2"
to ¾" and cut to 45" to cap the back hinge support. Install by
gluing and countersinking 1-1/2" #8 woodscrews. To complete the cap cut a
piece of 1" x 4" cedar to 45" and install on the upper face
using glue and 1" 18-gauge brad nails.
Use tongue and groove cedar to finish the sides and upper face of the box.
Glue and pin using ¾" 18-gauge brad nails. To finish the corners cut
1" x 4" cedar to 3/8" thick and rip to 1-3/8" for the
front edge and 2" for along the base. To complete the front base rip 1 x
4 cedar to 2" and install on the sides and bottom using glue and brad
nails.
To finish the lid rip a piece of 1 x 4 cedar to ¾" and attach to the
edge with glue and brad nails. Complete the lid surface by installing 1 x 4
cedar ripped to 2" and insert tongue and groove panels.
Fill all nail holes with wood filler sand and apply clear-coat to all
surfaces. Install safety hinges (inside box) to finish.
