Photo: Wendell T. Webber
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Using a 3/8-inch bit, create an entry hole for the jigsaw blade inside each handle mark. Cut out each handle and ease the edges of the holes with a rasp.
Using a 1 5/8-inch trim head screws and wood glue, glue and screw the 1x4 sides with the handles to the outside edges of the tray bottom. Glue and screw the 23-inch 1x3s onto the outside edges of the tray bottom and 1x4 sides. Install two 10½-inch cleats to the bottom of the tray 1 inch from each end. These will keep the tray from sliding off the box.
Using a 1 5/8-inch trim head screws and wood glue, glue and screw the 1x4 sides with the handles to the outside edges of the tray bottom. Glue and screw the 23-inch 1x3s onto the outside edges of the tray bottom and 1x4 sides. Install two 10½-inch cleats to the bottom of the tray 1 inch from each end. These will keep the tray from sliding off the box.
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