How to build a wooden puzzle storage box with removable trays

How to Build a Wooden Puzzle Storage Box with Removable Trays

A wooden puzzle storage box with removable trays is a practical and stylish way to store jigsaw puzzles, board game pieces, or small craft supplies. This step-by-step guide will walk you through the process of building a sturdy, functional box with sliding or lift-out trays.

Materials and Tools Required

Materials

• ¾-inch plywood (for the main box)
• ¼-inch plywood (for trays and dividers)
• 1×2 wood strips (for trim and support rails)
• Wood glue
• Brad nails or screws
• Drawer slides (optional, for sliding trays)
• Hinges and latch (if you want a lid)
• Sandpaper (120 and 220 grit)
• Wood stain or paint (optional)
• Clear finish (polyurethane or shellac)
• Handles or knobs (optional)

Tools

• Circular saw or table saw
• Jigsaw (for cutouts, if needed)
• Router (optional, for rounded edges)
• Clamps
• Hammer or nail gun
• Drill and drill bits
• Measuring tape
• Square ruler
• Paintbrush or rag (for stain/finish)

Step 1: Plan and Measure

Decide on the dimensions of your box based on the size of your puzzles. A good starting size is 24″ L x 16″ W x 10″ H, but you can adjust it to fit your needs. Each tray should be slightly smaller than the interior of the box for easy removal.

Sketch a basic plan, including:

• The main box
• The number of trays
• Whether the trays will slide on rails or stack inside

Step 2: Cut the Wood Pieces

For the Main Box:

• Cut two side panels from ¾-inch plywood.
• Cut a bottom panel of the same material.
• Cut two end panels for the front and back.

For the Trays:

• Cut the tray bases from ¼-inch plywood.
• Cut 1×2 strips for the tray sides.

For the Lid (Optional):

• Cut a piece of ¾-inch plywood slightly larger than the box opening.

Make sure all pieces are accurately measured and cut to ensure a snug fit.

Step 3: Assemble the Box

1. Attach the Sides – Apply wood glue along the edges of the bottom panel and attach the side panels.
2. Secure the Ends – Attach the front and back panels using screws or brad nails.
3. Reinforce the Corners – Use wood glue and clamps to hold the joints together while the glue dries.

Step 4: Install Tray Supports

Decide how you want the trays to be stored:

• Sliding Trays: Attach wooden rails or drawer slides inside the box.
• Stackable Trays: No rails needed; just ensure enough space between trays.

For sliding trays:

• Cut 1×2 strips and attach them to the inner walls, evenly spaced.
• Alternatively, install small drawer slides for smoother movement.

Step 5: Build the Trays

1. Attach 1×2 strips to the sides of each ¼-inch tray base.
2. Reinforce with brad nails or screws.
3. If needed, add dividers inside the trays for puzzle pieces.

Step 6: Attach the Lid (Optional)

• For a hinged lid, install hinges at the back.
• For a removable lid, ensure a snug but easy-to-lift fit.

Step 7: Sand and Finish

1. Use 120-grit sandpaper to smooth rough edges.
2. Follow up with 220-grit sandpaper for a fine finish.
3. Apply wood stain or paint for the desired look.
4. Seal with polyurethane for durability.

Step 8: Add Handles and Latch

• Install handles on the sides for easy carrying.
• If using a lid, add a latch to keep it secure.

Final Thoughts

This wooden puzzle storage box will keep your puzzles organized while adding a handmade touch to your home. You can customize the design with extra features like engraved labels or decorative trim.

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