Toolboxes are usually bashed-up, rusting metal boxes – but why not make yourself an upgrade? Inspired by the traditional Japanese wooden toolbox with its integrated handles and a clever sliding lid, this project uses recycled pallet wood to construct a practical storage box.
How to make a DIY wooden box
Gather your supplies
- Timber pallet (or other 22mm thick wood pieces)
- Wood glue
- 14g x 75mm galvanised hex head bugle screws
- Countersink drill bit
- 40mm nails
- Wax or clear coat to finish
You’ll also need
- Claw hammer
- Planer
- Clamps
- Circular saw
- Tape measure
- Random orbital sander with 40-grit sanding discs
- Cloth
- Drill
- Masking tape.
Safety note
When operating power tools, wear safety glasses, a mask and earmuffs, and tie your hair back.
Step 1
Pull apart the pallet using a claw hammer, removing any fasteners. Plane the edges of the pallet boards straight, ready to glue together.
Step 2
Position boards edge to edge to make four panels for the ends, sides, base and top (see the list of components, at left). Apply wood glue and clamp flat to dry. Cut pieces to size, setting the circular saw to 45° to bevel handles and lid lock.
Step 3
Sand panels with 40-grit sandpaper and wipe clean with a cloth. We did a light sand for a rustic look.
Step 4
Position an end piece against a side piece, inset 22mm from the side’s end. Predrill holes with a countersinking bit, then apply glue and secure with bugle screws into each board. Repeat for other end and side, insetting the end by 22mm. Predrill, glue and screw together to create a box frame.
Step 5
Position the base over the box frame, flush with the side edges. Predrill, then glue and screw to attach.
Step 6
At the ends, position the handles flush with the top, long sides of the bevels facing out to create handholds. Apply glue and secure with nails.
Step 7
On the top of the box, position a cleat flush at each end, then apply glue and secure with nails.
Step 8
To make the lid lock, slide the lid under a cleat to stop against the end. Use the cleat as a guide to mark a line on the lid. Centre a wedge on the line, long side of the tapered bevel facing outwards, then glue and nail.
Step 9
Position the lid with the wedge against the cleat, slide in the loose wedge to complete the lock so it pushes the lid under the opposite cleat. (Add a loop of tape to hold the loose end of the lid to prevent it from falling.) Use the cleat as a guide to mark a line, centre the lid stopper against the line, glue and nail.
Step 10
On the toolbox’s base, centre the feet, 22mm in from the ends, then apply glue and nail into the sides through the base. Use a wax or clear coat to finish.
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