p i r at e ' s c he s t t oy box

What You'll Need

lumber

1 - 1x2x4 1 - 1x2x8 1 - 1x3x2 2 - 1x3x8 1 - 1x6x4 1 - 3/4 x 2 x 4 sheet of plywood 1 - 3/8 or 11/32 x 4 x 8 sheet of beadboard paneling 1 - 9/16 x 8 feet quarter round moulding 1 - 1/4-inch round dowel
(availability will vary)

hardware/supplies

About These Plans

On this first page you will see above the project complete. On one of the last two pages you'll find the finished outer dimensions. Be sure to read ALL of the project steps before you start. To the right is a list of the Lumber, Hardware/Supplies, and Tools you will need to complete this project. A measuring tape and pencil are not included because that should be pretty standard and self explanatory. Below What You'll Need is the Parts list. This also is included on the Cutting Diagram page, which is the next to last page of this plan document. Also on the Cutting Diagram page is an estimate of the cost of the lumber. This estimate doesn't include any other supplies and does not factor in sales tax. Throughout these plans you'll find the icons below: indicates a diagram detailing the dimensions of a project part Layout This and/or the placement for pocket holes, screws, nails, etc.

tools

1 1/4" brads Kreg 1 1/4" pocket hole screws 1/2-inch, 3/4-inch brads 3, 2 1/2-inch hinges 2 safety lid hinges (left and right) wood glue, construction adhesive wood filler, choice of finish

table saw, miter saw, jig saw, sander/belt sander, drill/driver, Kreg Jig, clamps, strap clamp, square, flexible metal ruler or thin strip of scrap

Parts
bottom end rails (2) - 3/4 x 2 1/2 x 12 top end rails (2) - 3/4x 1 1/2 x 12 end stiles (4) - 3/4 x 1 3/4 x 11 3/4 bottom side rails (2) - 3/4 x 2 1/2 x 27 top side rails (2) - 3/4 x 1 1/2 x 27 center side stiles (2) - 3/4 x 2 1/2 x 7 3/4 side stiles (4) - 3/4 x 2 1/2 x 11 3/4 bottom - 3/4 x 15 1/2 x 30 1/2 corner blocks (4) - 3/4 x 2 1/2 x 2 1/2* end panels (2) - 3/8 x 9 1/2 x 15 7/16 side panels (2) - 3/8 x 9 1/2 x 29 11/16 lid ends (2) - 3/4 x 5 3/8 x 17 lid rails (3) - 3/4 x 1 5/8 x 30 1/2 starter lid slat - 3/8 x 2 1/8 x 32 lid slats (9) - 3/8 x 1 7/8 x 32 lid trim (2) - 3/8 x 1 5/8 x 32 hinge trim - 3/8 x 1 1/2 x 32 safety hinge blocks (2) - 3/4 x 1 1/2 x 15 1/2 straps (9) - 1/16 x 3/4 x CTF** *mitered corners, **cut to fit
All parts are listed in actual dimensions. Refer to the Cutting Diagram on the last page ofthis plan as a guide for determining the specific board from which to cut the parts.

take care!
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NOTE

Notes are the instructions for a particular step/section of the project. This indicates when to pay close attention to the diagrams, take precautions for safety, etc.

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Chris Hill/Chief's Shop 2013

Page 1

pirate's Chest Toy box

NOTE

Layout

Use the layout for creating the Top End Rails and Bottom End Rails. Set your Kreg Jig and drill bit for 3/4" stock.

NOTE
Apply glue to the ends of the rails, position as shown, and attach using 1 1/4" pocket hole screws.

NOTE
Use the layout for creating the Top Side Rails and Bottom Side Rails. Set your Kreg Jig and drill bit for 3/4" stock. Use the layout below for creating the hand opening on one Top side Rail.

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Chris Hill/Chief's Shop 2013

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p i r at e ' s c he s t t o y b o x

NOTE

Layout

Use the layout for creating the Center Side Stiles. Set your Kreg Jig and drill bit for 3/4" stock.

NOTE
Apply glue to the ends of the Center Side Stile, position as shown, and attach using 1 1/4" pocket hole screws. Create a second assembly using the Top Side Rail without the hand opening.

NOTE
Apply glue to the ends of the rails, position as shown, and attach using 1 1/4" pocket hole screws. Repeat with the second assembly.

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Chris Hill/Chief's Shop 2013

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p i r at e ' s c he s t t o y b o x

NOTE

Layout

Use the layout for creating the Bottom. Set your Kreg Jig and drill bit for 3/4" stock.

NOTE
Apply glue to the edges of the Bottom and position as shown at left. Attach using 1 1/4" pocket hole screws.

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Chris Hill/Chief's Shop 2013

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p i r at e ' s c he s t t o y b o x

NOTE

Layout

NOTE

Use the layout for creating the Corner Block. Cut a 45-degree miter to create them.

Apply glue to edges of the Corner Blocks and position them as shown. Attach using 1 1/4" brads.

NOTE
Apply glue to the inside of the End Assemblies and Side Assemblies, position the End Panels and Side Panels as shown, and attach using 3/4" brads.

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Chris Hill/Chief's Shop 2013

Page 5

p i r at e ' s c he s t t o y b o x

NOTE
These two steps are optional, which is why they're not listed in the parts list, and is here mainly as a means for covering the exposed edges of the beadboard paneling/ply. Cut 9/16" quarter round to fit on the edge of the back Side Panel and two End Panels (miter at the corners). Cut a 1/4-inch dowel to fit on the edge of the front Side Panel. The dowel is used because the quarter round would interfere with the hand opening. Attach all parts using glue and 3/4-inch brads. Feel free to cut trip to fit exactly over these edges.

NOTE

Layout

Use the layout for creating the Lid Ends. Use a flexible metal ruler or thin strip of scrap to create the curve. Cut it using a jigsaw.

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Chris Hill/Chief's Shop 2013

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p i r at e ' s c he s t t o y b o x
A note when ripping the Lid Rails: Go ahead and rip the strips needed for the Straps (see the Cutting Diagram and Parts List). Rip to allow for three strips 1/16" thick. Then rip the Lid Rails. You can skip ripping the Straps if desired, and simply use edge banding/veneer.

Layout NOTE
Use the layout for creating the Lid Rails. Set your Kreg Jig and drill bit for 3/4" stock.

NOTE
Apply glue to the ends of the Lid Rails, position as shown, and attach using 1 1/4" pocket hole screws.

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Chris Hill/Chief's Shop 2013

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p i r at e ' s c he s t t o y b o x
A note on cutting the Lid Slats: I cut these so that each piece had the beaded part of the paneling. This helped create a more detail look to the top. You may need to adjust the cuts slightly from what you see on the Cutting Diagram.

NOTE

Apply glue to the top of the curve on the Lid Ends and position the Starter Lid Slat flush with the ends of the Lid Assembly and against the Lid Rail as shown. Attach to the Lid Ends using 1 1/4" brads.

NOTE
Apply glue to the top edge of the Starter Lid Slat and place a Lid Slat flush against it. Attach to the Lid Ends using 1 1/4" brads. Continue the same process for the subsequent Lid Slats. When all have been attached, place a strap clamp around the assembly centered on the two Lid Rails. Tighten the clamp just enough to close up any gaps that may be between the Lid Slats. DO NOT over tighten.

NOTE
Apply glue to the outside face of the outer Lid Rails, position the Lid Trim flush the the rails, and attach using 3/4-inch brads.

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Chris Hill/Chief's Shop 2013

Page 8

p i r at e ' s c he s t t o y b o x

NOTE
Apply construction adhesive (I used clear) to one face of the Straps, position flush with the edge of the Starter Lid Slat, clamp in place and wrap over the top of the lid to the last Lid Slat, clamping in a couple of spots as you go. Repeat for each strap. Allow the adhesive to set. You can follow up and drive in a few 1/2-inch brads. I used decorative copper nails on one I built for my nephew. Be sure to cut off the ends of any brads or nails (a Dremel works well) that protrude through the Lid Slats.

NOTE
Apply glue to the face of the back Top Side Rail and attach the Hinge Trim using 3/4-inch brads.

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Chris Hill/Chief's Shop 2013

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p i r at e ' s c he s t t o y b o x

NOTE
I simply attached three hinges as shown at left, using a 1/8" thick piece of scrap (a paint stir stick is roughly that size) as a spacer for the barrel of the hinge. Feel free to apply the hinges as you desire.

NOTE
Attach two safety hinges to the End Panels and Safety Hinge Blocks, following the hinge manufacturer's directions. You will need to get a left side version and a right side version. The safety hinge will allow the lid to stay upright and not slam down. I also added felt furniture pads to the top edge of the rails for an even softer close.

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Chris Hill/Chief's Shop 2013

Page 10

p i r at e ' s c he s t t o y b o x
Parts
bottom end rails (2) - 3/4 x 2 1/2 x 12 top end rails (2) - 3/4x 1 1/2 x 12 end stiles (4) - 3/4 x 1 3/4 x 11 3/4 bottom side rails (2) - 3/4 x 2 1/2 x 27 top side rails (2) - 3/4 x 1 1/2 x 27 center side stiles (2) - 3/4 x 2 1/2 x 7 3/4 side stiles (4) - 3/4 x 2 1/2 x 11 3/4 bottom - 3/4 x 15 1/2 x 30 1/2 corner blocks (4) - 3/4 x 2 1/2 x 2 1/2* end panels (2) - 3/8 x 9 1/2 x 15 7/16 side panels (2) - 3/8 x 9 1/2 x 29 11/16 lid ends (2) - 3/4 x 5 3/8 x 17 lid rails (3) - 3/4 x 1 5/8 x 30 1/2 starter lid slat - 3/8 x 2 1/8 x 32 lid slats (9) - 3/8 x 1 7/8 x 32 lid trim (2) - 3/8 x 1 5/8 x 32 hinge trim - 3/8 x 1 1/2 x 32 safety hinge blocks (2) - 3/4 x 1 1/2 x 15 1/2 straps (9) - 1/16 x 3/4 x CTF** *mitered corners **cut to fit
All parts are listed in actual dimensions. Refer to the Cutting Diagram on the last page ofthis plan as a guide for determining the specific board from which to cut the parts.

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Chris Hill/Chief's Shop 2013

Page 11

cutting DIAGRAM

p i r at e ' s c he s t t o y b o x

Estimated lumber cost: starting at $11 0

take care!
Follow ALL SAFETYGUIDELINES AND RECOMMENDATIONS provided by the manufacturers ofyour tools, and any chemicals such as glue and finishes you use in this project. YOU are responsible for your safety, so use common sense when working in the shop!

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Chris Hill/Chief's Shop 2013

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