Project 9: Create a Wooden Lock Box.

2018-07-28

Objective:

To create a wooden lock box. Objective is to build a box that can be used for children to practice manipulation of a combination lock and provide a space for their valuables. Box could be made more secure by bolting to a wall.

Only hand tools were used to build this stand. The box was made out of 2x4s lumber and 3x4 plywood, with wood screws, door hinge and double hinge clasp hardware.

Structure:

4 in. High

11.25 in. Deep

8.75 in. Wide

6.5 lbs Mass

Materials:

1. 1x 2" X 4" X 8' Southern Yellow Pine (SYP) Lumber. Cost $3.98 ea.

2. 3/4" X 2' X 4' Plywood. Cost $15 ea.

3. 8x #10 2.5" Wood Screws. Cost $1.00.

4. 6x #10 2" Wood Screws. Cost $0.60.

5. 4" Door Hinge. Cost $2.58 6. 3" Double Hinge Clasp. $Cost 3.73. 7. Wood Glue. Cost $0.25

8. Oil Based Primer. Cost $2.00.

9. Oil Based Paint. Cost $2.00.

Total cost of all materials used $31.35 USD.

Tools:

1. Makita 7 1/4 Circular Saw, est. cost $100

2. Makita Orbiting Sander 5.0" VSP, est. cost $79

3. Ryobi Jig Saw, est. cost $69

4. 3/8 Drill, corded, est. cost $50

5. Black Oxide Drill bit Set (29-Piece). est. cost $27

6. 2x 4in C-Clamps, est. cost $12 ea.

7. 2x 8in C-Clamps, est. cost $15 ea.

8. 1x 12in F-Clamp, est. cost $11 ea.

9. Aluminum Speed Square, est. cost $8

10. 25' Tape Measure, est. cost $10

11. 18" Stiff Ruler, est. cost $8

12. Screw Driver Interchangeable Set, est. cost $7

13. Screw Driver 3/8 X 8", est. cost $8

14. 9" polycast torpedo level, est. cost $3

15. Wood Chisel, est. cost $5

16. 8 in. Slip Ring Pliers, est. cost $9.97

17. 8 in. Long Nose Pliers, est. cost $ 5.17

18. Purdy 2.5" White Bristle 100% Natural, soft, est. cost 14.47

19. 2" Putty Knife, est. cost $7.97

20. Safety Knife, est. cost $6.98

21. Paint Spinner, $9

22. Hammer, Straight Claw, cost $10

Total cost of all tools if all bought new for project is approximately $500 USD.

Procedure

1. Cut 2X4 lumber to length:

2x 5.75 in. long

2x 11.75 in. long

2. Cut 3/4" plywood to shape:

2x 11.75 in. long by 8.75 in. wide

3. Lay the 2x4's in a box shape and make sure fit is good.

4. Apply glue to each end of cross member and refit. Clamp using the 12in F-Clamp.

5. Drill eight pilot holes, two per corner, on the vertical member surface, centered on the cross member. First drill 1/8" pilot hole 2.5" deep, next drill 3/16" through the vertical member, and then add counter bore using 1/2" drill bit.

6. Screw in the eight #10 2.5" Wood Screws.

7. Place bottom plywood. Predrill for a 2.0" wood screw using drill sizes listed in step 5.

8. On top rear cross member mark out pocket for the hinge, 0.188" deep and 4" (2 3/8" both end).

9. Using jigsaw make cut 1/8" along pocket. Use hammer to break out wood slices. Then chisel out bottom of pocket.

10. Install 4" hinge.

11. Install the double hinge clasp at the boxt top plywood.

Conclusion

Just add whatever lock you prefer and you're done.