Build a Deck Box

Clamp a front/back frame (C/D) flush with the inside faces of the legs with the pocket holes facing out (Drawing 2). Glue and screw the frame to the legs. Repeat for the other frame and check that the assembly is square. Apply braces and clamps as needed to square the box until the glue dries.

Working from the center slat to the ends, glue and nail bottom slats (G) spaced about 1/8 inch apart.

Measure the height of the front/back frames and end frames and cut 10 pieces of end cladding (H) to length.

Using the same technique as the end frames, center a piece of front/back cladding (I) on the front/back frame (C/D) (Drawing 4). Glue and nail it in place. Working out from the center to the edges, add the remaining cladding pieces spaced evenly apart. Repeat for the opposite frame.

Rip the trim cladding (J) to width and cut each piece to length. Glue and nail them in place (Drawing 4).

Measure between the side ledges (M) and cut the back ledge (N) to length. Drill pocket holes as shown (Drawing 5). Glue and screw the back ledge with the outside face flush with the outside edge of the back trim (L).

Use the same method as in the previous step to cut a front nosing (P) to length. Glue and nail the front nosing in place. Then repeat Step 3 to add the other end nosing.

Measure between the end lid cleats and cut the back lid cleat (R) to length. Glue and nail the back lid cleat in place.

Measure from the back lid cleat (R) inside edge to the frame rail (B) inside edge and cut the center lid cleat (S) to length. Drill pocket holes on both ends. Mark the center of the back lid cleat and the front rail. Then glue and screw the center lid cleat in place.

Cut the side lid nosing (V) to length. Glue and nail the edging in place on the slats (Drawing 8). Repeat for the other lid.

Measure between the side lid nosing pieces (V) and cut the back lid nosing (W) to length. Drill pilot holes, add glue, and screw the back lid nosing to the slats using 1-5/8-inch exterior screws.

Measure between the side lid nosing pieces (V) and cut the front lid nosing (X) to length. Glue and screw the front lid nosing to the slat ends (Drawing 8). Repeat for the other lid.

Temporarily remove the lids and fill each nail hole with putty. Sand smooth and wipe the surfaces clean.

Apply the finish of your choice to the lids and box. If you choose paint, prime the wood first, sand the primer smooth, and add a second coat of primer where needed. Then paint.

Nail nylon furniture glides centered on the bottom of each leg. Then reinstall the lids.