Boxes can be made in a variety of shapes, sizes and materials. Making boxes is a good way to base metal or wood work. This project is very simple to complete and introduces you to the machines and tools related to the craft. Follow these instructions to create a simple box that has many uses.
Method 1 of 2: Making a Metal Box
Step 1. Prepare sheet metal
It's best to use a metal that's thick enough to make the box sturdy, but thin enough to bend. Metal pipe is a good material. You'll start with a square cut.
Step 2. Measure the cut and the curve
Draw draft lines on your sheet metal to mark the parts you will cut and bend. You'll be bending all four sides up to create the walls, so measure the same lines, parallel to the edges. These lines will mark the bent part of the wall.
You'll also bend the top of each wall to hide any sharp edges. Draw a parallel line a little distance from each edge down.
- Mark the same square on each end of the square. This square may have been formed from the indentation lines that have been drawn earlier. This box will be cut to form the wings that become the sides of the box.
Step 3. Cut out the entire square
Clamp the sheet metal on the workbench so that it does not shake or vibrate during cutting. Use a jigsaw or other metal saw and cut slowly to make sure you cut straight lines.
Step 4. Bend the top edge inward
After all the squares are cut, you will have four wings left. Bend the edges of the entire wing to create a smooth edge for the top of the box. Insert the first edge into the bending machine. Make sure the arrangement matches the line you measured earlier. Bend the edges 90°. This will make the mouth part.
If you don't have a bending machine, lay the sheet on the edge of the table and place a piece of wood on it. Clamp the wood on the table as tightly as possible. The piece of wood will provide support for the bending machine so that the metal can be bent by hand or with a hammer.
Step 5. Hammer the mouthparts inward
Continue the folding process by hammering the lip inward so that it matches the wing. Repeat this process on all four wings.
Step 6. Bend the part of the wall up
Now that the top of the wall is finished, it's time to lift it up. Insert one part of the wing into the bending machine, arrange it according to the bend line that has been measured earlier. Bend the wall up at a 90° angle. Repeat this step for each section of the wall.
Step 7. Secure all corners
At this stage, your box looks almost finished. The four walls have been bent upwards, and the edges have been folded inward. Now you need to secure the entire corner with smaller pieces of metal.
Measure the height of the box. Cut four strips of metal, each metal should be long enough to reach from the bottom to the top of the box, and wide enough to bend in half (usually about 2.5 cm or so on each side, so about 5-7.5 cm wide).
Insert each strip into the bending machine, half inside and half outside. Bend each strip lengthwise to form a 90° angle.
Step 8. Attach the corner safety plates
Once bent, place the safety plate into the corner of the box, and make a hole through the plate and box. Make two holes on each side of the fold, at the top and bottom. Use rivets for each hole. Use a hammer or nail gun to attach these nails.
Once all the nails are done, the box is finished.
Method 2 of 2: Making a Wooden Box
Step 1. Measure your wood
You need to make sure that all the pieces of the wall are the same height. The opposite side of the wall also needs to be the same length. You'll also need a bottom piece that fits inside the finished box.
Step 2. Prepare the corners
At the cut end of the wall, cut each edge at a 45° angle from the inside. These 45° angles will meet and form an angle that has no gap.
Use right angled joints to form right angles. This will create a smooth segment. When cutting at a 45° angle, make sure you don't affect the entire length of the wall cut
Step 3. Prepare a long piece of plaster
Lay each wall piece side by side on top of the plaster so that the edges touch each other. The pieces are laid out as if the walls of the box were torn down.
Step 4. Glue the bottom to one of the walls
Allow the glue to harden and apply pressure using tongs. Once the glue has hardened, apply glue to the remaining corners that are visible in the bottom cut.
Step 5. Apply glue to the corners
Apply strong wood glue to the wall at a 45° angle. Cover the edges with paper before applying glue to strengthen the bond.
Step 6. With the glue applied, roll the wall up until the 45° angle fits over every other wall
If the calculations are correct, the bottom piece will fit into the wall pieces. Pinch each side and let the glue harden.
Step 7. Add the cover
You can make a simple cover by measuring a piece of wood that is wider than the edge of the box. Glue small pieces of wood around the edges of the new pieces to keep the cover from falling off.
Step 8. Decorate your box
You can bend the edges down if you want the box to be more curved. Paint the box as you wish.