This project came about as a result of a group collaboration with more than twenty other woodworkers on YouTube. The idea was to make a project entirely from scraps of wood and make a video of the build, and to post them all on the same day. I had done the same thing before with the bookends video and found that to be an interesting experience.

Here’s the video:

I started with some pieces of 2×4 that were end cuts from work I did on my house. They had been taking up space on the bottom shelf of my lumber rack since the springtime.
I cut these into strips, 1/2″ x 1/2″, then cut those to length for the sides and ends:

Along with the 2×4, I found a short piece of 2×6 to make the bottom panel for the box, and here I’m using my new clamps to glue that up:

The bottom panel cut to size with a rabbet cut around the edge.

The box goes together like a log cabin, to form box joints on the corners. First, I scorched each piece with a torch to mimic wear and erosion to make the box look old:

The box part done. This method for making a box can be used for something less rustic to form perfect fitting box joints.

The ends of the lid are curved and I used the dimension sheet (available HERE) to lay that out:

Connect the dots and cut it out.

Assembly started on the lid:

The slats for the lid are cut on one edge with a slight angle, as shown on the dimension sheet.

Then it’s just to glue and pin them in place up and over the lid:

Fully assembled:

The box will be stained later to even out the colour.

For the hinges, I wanted something very simple and made from wood. I started with these pieces:

Then rounded the end of the longer part with a sharp knife.

And cut the pivots out:

The bar is glued and screwed to the back of the box.

And the pivots are glued and screwed to the lid:

This will be scorched as well, to match the box.

To lock the box, I thought I would do something neat by making my own wooden key operated lock, rather than a metal hasp and padlock. It took a lot of messing around to come up with something that worked well, but the process was very interesting.
I started with some scrap 3/4″ Baltic birch plywood that I cut to 3/16″ thick:

I then laid out two 1-1/4″ circles with a forstner bit to cut out:

I made a 3/16 hole in one, and a slot in the other.

The one with the hole needs a pin and I made that from maple, whittled down to size:

A test to get the spacing right.

The lock parts go into a piece of 1/2″ plywood with two 1-1/4″ counterbores:

Then trimmed down to size.

The key is made from the 3/16″ plywood as well:

The finished lock:

The lock mounts inside the box and a small oval hole is drilled through, then scorched:

The lock is simple, but works well.

To make handles, I cut some of the scrap from making the bottom 3/8″ thick and dilled 1″ holes:

Then smoothed roughly with the carving knife.

Finished and scorched:

The hanger brackets get glued onto the sides of the box, with the ring inside.

Ready for stain:

First, I brush off any lose charred wood.

Then wipe on a coat of mahogany stain:

I let the stain dry for a few hours then spray on a coat of oil based satin urethane.

I lined the box with cedar scraps left from making my deck chair:

I glued cleats in the lid for the catch mechanism for the lid liner. The liner is a single panel that encloses the lid and creates a “secret compartment”.

The lid liner also engages the latch on the lock:

The catch for the lid is a spring loaded block and is released (as shown in the video) with a small drill bit or paper clip.

Finished:

Several others participated in the “Scrap Wood Challenge” by making a project and video:

April Wilkerson,
Steve Carmichael,
Peter Brown,
Fr. Thomas Bailey,
Dominic Bender,
Manhattan Wood Project,
Arzensek Andrea,
Steve French,
Jason Rausch,
AdventuresInDIY,
Fabian’s Tiny Workshop,
Nick Ferry,
Richard Morley,
Patrick’s Work Shop,
Darbin Orvar,
Rock-n H Woodshop,
Carl Jacobson,
The Nomadic Polywright Show,
McGinn’s WoodShop,
Jack Houweling,
Mike Fulton,
Ted Alexander,
Average Joes