The box is 4mm ply off cuts and pallet boards I collected from CFI Industries in May this year 2026 Pine pallet boards and Ply off cuts
The ply
Advance to late June 2026 now I cut the ply and timber into even smaller pieces. All with the intention to distract myself away from my euro hinge dilemma and looking for Pottzys dead Sander.
I had originally intended to use quad internally but due to not knowing what I was doing I made a really dopey mistake and glued all the quad on the box base. The goof up
The first Test Jig Overnight in bed I had a amazing brainwave thinking I could resurrect my mistake by making a jig and cutting the four corners off with a 38mm forstner bit allowing the vertical quad to fit in the recess.and was to be the beginnings of the savior Jig! What it was supposed to do was the two holes were on top of each other, the lower 38mm hole was C shaped to fit around the ply base fitted around the quad the second piece sat directly on top guiding the bit as a complete hole. A Brilliant plan I thought, however when the bit passed the guide hole it decided to take the easy option and try to exit out the cutout. This resulted in a tapering hole heading towards the inside of the ply. My second try was not much better but had possibilities, the third was a 3 strikes and your out!
The jig went straight into the rubbish and the ply sheet introduced to the table saw, hence I dont have any picture to show instead you have to wade through this Jibber.
I turned to the pallet wood and sawed up a heap of triangle bits to use inside instead.
The second test Jig Then made test Jig to ensure I didn't screw up again I was on my way at last, half a day wasted just fooling around.
I also cut some 90 deg strip for the outside
I was on a roll! The Frame is developed
Nothing too much of the grey matter required here. I used my corner clamps to hold everything in place and a hammer to align everything perfectly
The top was then aligned with ratchet clamps. Some my remember "Big Al" from Lumberjocks days, well he posted some modified ratchet straps as a project/Blog of which I still use today. See the credits to him on the strap. I then trimed it to size and fitted the base and edge trim. It required to be notched to fit correctly.
I finished the trim work and then made my patented Knuckleduster handles, (hence the fighter box)
Routed all the sharp edges off Then fitted rubber feet
Dimensions The overall sizes are 505 mm x 360 mm
Finishing I used some decking oil to complete the job. Whats it for? who knows
