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Author: Cori_Nicholls, Contributing Editor
| If you are working from sheet masonite, you will want to cut it into the size that you want your box to be - cut the two pieces to the exact same size. (If you were lazy, like me, and bought pre-cut masonite, you can skip this step).
Once you know your masonite sizes, you can measure and cut your boards. You need to subtract the depth of the bottom groove from the legnth of the side of the masonite to calculate the length the board should be. That bottom should fit int here snuggly so measure twice cut once...and remember that it is better to cut the length a touch too long than a touch too short. (If you or someone you know is a handy woodworker, you should know exactly what I am talking about with these measurements. I am not good at math and my father did most of this part - I can only translate what I saw him doing) The ends of the board should be cut at a 45 degree angle so the mitres will fit together snuggly. The board should look like the following image once cut. |
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| Once all of the cuts have been made, You need to join them together. Fit the masonite board into the bottom grooves of two of the pieces that will be joined. Add some wood glue to the edges that will be joined and, using the hammer, secure the corners together with the finishing nails.
Handy Tip: Drill small pilot holes for the finishing nails so you will not split the wood. Then work your way around the masonite with the other boards until all four sides of the box are formed. |
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 | Once the box has been glued and nailed together, add a corner brace to the inside of each corner for extra strength.
At this stage, you can also install the half turn buttons around the top edge of the box. These will hold the lid firmly in place. A Tip for your Lid: Drill a small hole in one of the corners. Just large enough for the tip of one of your fingers. This will make it MUCH easier to lift the lid out of that groove along the top. |
| Now for the foam. Cut a piece of each type of foam. The thin foam will need to fit flat in the bottom of the box. the thicker foam will be attached to the underside of the lid (it can be your preference whether you glue the foam to the lid of not. If you leave it loose it makes it easier to replace if necessary)
Decide how you want to divide the box up. It isn't necessary to install wooden dividers, like I did, but you may find it is a nice way to keep your colours separated. Optional Additions:
Voila - there you have it - the perfect Travelling Studio Box. Now for some photos and sketches... We can start with my sketches...when designing any kind of box, I always put it down in my sketchbook and dream a bit...I have a separate sketchbook just for this. |
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