ARTICLE Mark Message PHOTOGRAPHY Scott Espie TOY CHEST PLANS Gareth Poley MATERIALS for this project were kindly supplied by Refresh Renovations.
- 1 x SHEET CUSTOM BOARD (MDF)
- OR PLY 2400 x 1200 x 12mm (minimum)
- 5 M PINE SQUARE MOUNDING 25 x 25mm
- 2 x ‘BUTT’, ‘GATE’ OR ‘SAFETY’ HINGES
- PANEL PINS
- WOOD SCREWS
- PVA GLUE
- CHAIN, ROPE OR SAFETY HINGE
- CIRCULAR SAW
- DROP SAW
- BENCH SAW (Optional)
- BATTERY DRILL/DRIVER
- TAPE MEASURE
- 'STRAIGHT EDGE ‘ (2.4m long minimum)
- PAINT BRUSHES
- STENCILS (Optional)
Measure and mark out cut lines on the ‘panel’ of choice using pencil, tape measure and straight edge.
If a bench saw is not available, you can set a ‘guide fence’ with clamps and a straight edge for a circular saw to follow to make straight cuts.
NOTE: The base panel is best fixed inside the upright panels and smaller side panels between front and rear panels to minimise visible joint lines, so the thickness of your panel will determine some measurements.
Use panel pins and glue to fix panels together. It is advisable to nail a minimum of 50mm in from ends to avoid splitting or delaminating.
Measure, cut and fix 25x25mm cleats with glue and wood screws to both sides in all corners to provide strength, stability and durability, fixing cleats to top edges of front and back panels will also help.
Fastening the lid to the chest with hinges can be done a number of ways and will depend on what type/style you have chosen. The easiest option is to fix ‘butt’ (as shown) or gate hinge leafs to outside faces of lid and back panels. If you prefer a concealed hinge, some rebating is required.
If you are using a concealed hinge, a robe or chain should be used to limit the lid’s opening.
For added safety, you might want to consider using soft close hinges instead like the one shown (available from www.samet.co.nz) or alternatively you could install a slow release safety hinge instead of the chain which would not only limit how much the lid can open but will also ensure the lid does not slam shut.
Adding castors and handles to your toy chest will add character and make it easier to use.