Step 1: Lay out the parts

lay out the parts
Photo: Wendell T. Webber
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Using a tape measure and straightedge, lay out the chest’s nine individual pieces on a half sheet of ½-inch birch veneer plywood: front, back, two sides, bottom, two roof sections, and two gable ends, using the measurements in the illustration.

Clamp the plywood to a worktable. Using a jigsaw, cut the front, back, two sides, and the bottom pieces.

To make the roof pieces, set the saw blade at a 26-degree angle. Cut along one long edge of each roof piece at that angle; when mated together, these cuts will form the angle of the peak. Cut all the other edges with the blade set straight at 0 degrees.

On each side piece, mark out a 3-by-3-inch square for the handle. Drill -inch holes inside the four corners of each square to fit a jigsaw blade. Using a jigsaw, cut out both squares. Also cut a -by-½-inch notch on the top back corners.

Cut each gable out of a 4-by-18-inch piece of plywood. Clip ½ inch off the back corner to match the notch in the side pieces.
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    Tools List

    • 30-foot tape measure
      Tape measure
    • combination square
      Combination square
    • straightedge guide
      Straightedge
    • adjustable clamp
      Adjustable clamps
    • safety glasses
      Safety glasses
    • jigsaw
      Jigsaw
    • random orbit sander
      Random-orbit sander
    • bar clamps
      36-inch bar clamp
    • hammer with nailset
      Hammer and nailset
    • drill
      Drill/driver fitted with -inch bit
    • putty knife
      Putty knife
    • paint brush and roller
      Small paint rollers and brush
    • Phillips screwdriver
      Screwdriver

    Shopping List

    1. 4-by-4-foot piece of ½-inch birch plywood

    2. 120-grit sandpaper

    3. Stainable wood glue

    4. Rag

    5. 4d finish nails

    6. Stainable wood putty
    7. Four 2-inch casters

    8. Satin-finish latex paint
    in red, white, and silver

    9. Painter’s tape

    10. 30-inch continuous hinge

    11. Two toy box spring lid supports
    (one left and one right)