Build a Deck Box

	Tools & Materials
	Prepare the Panels
	Assemble the Base
	Attach the Lid and Install the Floor
	Sand and Finish the Box

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Tools Circular saw or table saw Router optional Combination square Drill/driver Palm sander Clamps Tape measure Paintbrush Dust mask Goggles Hearing Protection

Materials 1"x6"x8' cedar — 13 pcs 1"x4"x8' cedar — 1 pc Wood glue 2 hinges Hasp 1 1/4" galvanized screws Sandpaper Varnish, paint or stain

See the Cut List.

1. Glue five of the 47" long 1x6 pieces together for the box's front panel and five for its rear panel. After the glue cures, cut the panels to 46"x25".

2. Glue five of the 23 3/4" long 1x6 pieces together for the box's left side panel and five for its right side panel. After the glue cures, cut the panels to 23"x25".

3. Glue the 45" long 1x6 pieces (there should be five) together to make the box's floor panel. After the glue cures, cut the panel to 23"x44 1/2".

4. Glue the 48" long 1x6 pieces (there should be five) together to make the box's lid. After the glue cures, cut the panel to 25"x47". Making the lid this size allows for a 1/2" overhang at the front and both sides of the box.

Use 3/4"x3/4" strips and screws to secure the panels.

1. Secure two 21" long 3/4"x3/4" strips to the inside face of the front panel. The strips should be positioned 3/4" in from each end of the panel, with the top end of the strip 1" below the panel's top edge. Drive the screws through the strips into the panel so they aren't visible from the box's exterior. Secure strips to the back panel in the same manner.

2. Secure the side panels by driving screws through the 3/4"x3/4" strips on the front and back panels into the inside faces of the side panels.

Make a mortise in the front panel for the hasp.

1. Position the hinges, evenly spaced, on the rear panel and mark for hinge placement.

2. Secure the hinges to the rear panel and the edge of the lid with the screws provided.

3. Install the hasp and keeper on the front of the box. Make a mortise in the top edge of the front panel to receive the hasp when the lid is closed.

Use 44" long 3/4"x3/4" strips to support the floor.

4. Position the floor panel inside the box.

5. Install a 44" long 3/4"x3/4" strip to the inside face of the front panel. Position the strip so it is centered from left to right on the panel with its bottom edge 1/4" up from the panel's bottom edge. Install a 44" long 3/4"x3/4" strip on the back panel in the same manner. Screw through the floor panel into the 44" long strips to secure the floor panel in place.

Sand the box as needed. You can paint or stain the box with any exterior grade finish. If you prefer to use a clear-coat, one of the best exterior, protective finishes for a project like this is exterior varnish. Varnish provides an excellent protective film for any surface that is used heavily or exposed to the elements. It flows well and has a relatively long curing time so it has time to self level. With its above-average leveling qualities you can easily achieve a high-quality finish with varnish.