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This chest will fit beautifully into any space and provides great additional storage for items such as blankets, pillows, toys and smaller items in the tray. It can also be used as a coffee table, entryway bench or at the foot of a bed. www.nickandalicia.com

Difficulty moderate

Tools

Kreg Tools

Other Tools

  • Circular Saw (corded)
    Circular Saw (corded)
  • Miter Saw
    Miter Saw
  • Square
    Square
  • Table Saw
    Table Saw
  • Tape Measure
    Tape Measure
  • Clamps
    Clamps
  • Drill (cordless)
    Drill (cordless)
  • Nail Gun
    Nail Gun
  • Sander
    Sander
  • Air Compressor
    Air Compressor

Materials

Wood Products

  • 6 Board , 1x6 , 96"
  • 4 Board , 1x4 , 96"
  • 2 Board , 1x2 , 72"
  • 2 Board , 2x4 , 96"
  • 1 Plywood or shelf board , 3/4" - 24" wide , 72"
  • 1 Board , 1x3 , 72"

Hardware & Supplies

  • 2 Chest Handles
  • 1 Chest Latch
  • 1 36" x 3/4" Continuous Hinge or alternative hinges
  • 1 Stain - Color: Provincial
  • 1 Polyurethane - Finish: Satin
  • 1 5" 80/120/220 grit Sandpaper Discs
  • 104 1 1/4" Kreg Pocket Hole Screws
  • 110 1 1/4" finishing/brad nails
  • 1 Wood Glue
  • 1 Safety Lid Support (optional)
  • 8 2 1/2" Kreg Pocket Hole Screws
  • 1 Wood Filler

Cut List & Parts

  • 4 1x6x96" boards , Cut to 8 - 47" lengths
  • 1 1x6x96" board , Cut to 1 - 47" board and 2 - 16 5/8" boards
  • 1 1x6x96" board , Cut to 4 - 16 5/8" boards
  • 1 2x4x96" board , Cut to 52" + 20" lengths with 45° angles on each end (see steps)
  • 1 2x4x96" board , Cut to 52" + 20" lengths with 45° angles on each end (see steps)
  • 1 1x4x96" board , Cut to 50" + 18 1/8" + 18 1/8" lengths with 45° angles on each end (see steps)
  • 1 1x4x96" board , Cut to 50" + 18 1/8" + 18 1/8" lengths with 45° angles on each end (see steps)
  • 1 1x4x96" board , Cut to 50" with 45° angles on each end + 4 - 9.5" boards with 45° angles on the face (see steps)
  • 1 1x4x96" board , Cut to 50" with 45° angles on each end + 4 - 9.5" boards with 45° angles on the face (see steps)
  • 1 1x2x72" board , Cut to 2 - 12" and 2 - 19" lengths with 45° angle on one end (see steps)
  • 1 1x2x72" board , Cut to 51.75" with 45° angles on both ends (see steps)
  • 1 3/4x24x72" shelf board or plywood , Cut to 11" + 50 1/4" lengths
  • 1 1x3x72" board , Cut to 12.5", 12.5", 15", 15" with 45° angles on each end (see steps)

Directions

  • Build the Base

    Drill 2 - 1 1/2" pocket holes on either end of the 2x4x20" boards at a 45° angle. Ensure that the base is square. Secure using wood glue and 8 - 2 1/2" pocket hole screws. Flip the base over so that the pocket holes not facing up.

  • Build Front & Back Panels

    Lay 3 - 1x6x47" boards on a flat surface. Mark the 28 pocket hole locations based on the sketch. Take note that the top board will only have pocket holes on the bottom of the board. Drill 3/4" pocket holes and then secure the boards with wood glue and 22 - 1 1/4" pocket hole screws. Repeat to create the second board.

  • Build Side Panels

    Lay 3 - 1x6x16 5/8" boards on a flat surface. Mark the 13 pocket hole locations based on the sketch. Take note that the top board will only have pocket holes on the bottom of the board. Drill 3/4" pocket holes and then secure the boards with wood glue and 13 - 1 1/4" pocket hole screws. Repeat to create the second board.

  • Build Base Panel

    Lay 3 - 1x6x47" boards on a flat surface. Rip two of the boards down to 4 3/4" wide. Mark the 18 pocket hole locations based on the sketch. Drill 3/4" pocket holes and secure the boards with wood glue and 18 - 1 1/4" pocket hole screws.

  • Assemble Box on Base

    Attach the side panels to the front and back panels using the pocket holes you drilled into the side panels with wood glue and 12 - 1 1/4" pocket hole screws. The side panels should be the outermost piece on each end and all panels should have the board without pocket holes at the top.

    Ensure the box is centered and square on the base. Secure with 1 1/4" pocket hole screws.

    Insert base panel from previous step and secure into the base along the bottom edges with 1 1/4" finishing/brad nails.

    *NOTE: Do not climb into the chest...if you do, you may get stuck. Don't ask how I know...

  • Add Base Trim

    Attach 50" and 18 1/8" boards with 45° on each end to the base. Continue around the bottom with another 50" and 18 1/8" board.

    Secure with wood glue and 1 1/4" finishing/brad nails.

  • Add Top Trim

    Repeat the same steps you just completed on the bottom, but this time flush with the top of the box.

    Secure with wood glue and 1 1/4" finishing/brad nails.

  • Add Corners

    Run each 1x4x9.5" piece through a table saw set at 45° along one edge only.

    Be careful not to take too much of the width of the wood off. Try to keep the cut as close to the face edge as possible.

    Secure with wood glue and 1 1/4" finishing/brad nails.

    Repeat on all 4 corners with 8 pieces, creating as tight of a joint as possible on each corner.

  • Build Tray Frame

    On the 2 - 1x3x12 1/2" boards, drill 2 - 3/4" holes (or larger if you'd like) in the center of each. Lay the box on a flat surface with all four pieces and glue all corners together. Check for square. Clamp together and let dry overnight.

  • Add Tray Base

    Cut down the 3/4x11x24" shelf board to 3/4x11x13 1/2". Drill 4 - 3/4" pocket holes, 2 on each side, into the tray base. Fit in place, and secure with 4 - 1 1/4" pocket hole screws.

  • Add Tray Shelf

    On the left side of the box, mark 4" from the top of the box on both the front and back panels. Attach 1x2x12" pieces to the front and back panels with wood glue and 1 1/4" finishing/brad nails.

  • Cut Top Panel

    Rip the 3/4x24x50 1/4" down to 3/4x18 1/4x50 1/4".

  • Trim Top Panel

    Carefully rip the 3/4" x 2" x 51 3/4" piece and 2 - 19" pieces down to 3/4" x 1". If you aren't comfortable ripping such a narrow piece on your table saw, you can always buy a wider piece of 1" wood (like a 1x6) and rip 1" off of it. The two 19" pieces should have 45° angles on one end. The 51 3/4" piece should have 45° angles on both ends.Use glue and brad nails to attach.

  • Attach Top and Insert Tray

    Attach the top using a 36" continuous hinge. Or you can purchase decorative hinges that can go either on the inside or outside of the top. Set your tray in place.

  • Install Safety Lid Support

    This is optional. However, it is highly recommended if you have young children in the house or if it's primary use is a toy box. Install the safety lid support as per the manufacturer's instructions. (Each manufacturer and Safety Lid Support style will vary)

  • Finishing Touches

    Install handles on each end. We used 2 3/4" zinc chest handles and spray painted them black. We found the chest latch at our local hardware store, however there are many options available online.

  • Filling, Sanding, Staining, Coating

    Fill all finishing/brad nail holes and any gaps on the corners. Sand starting with an 80 grit sandpaper on your orbital sander. Complete one pass and then complete another pass with 120 grit and finishing with 220. Stain in the color of your choice. We chose Provincial by Minwax. We did not stain the inside as we wanted the scent from the wood to remain. Protect with a polyurethane. We chose a satin finish so it would look more antique.