You will need:
Sheet of 20mmplywood or MDF/Supawood
Piano or continuous hinge with screws
Supplies: 8 x 5cm wallboard screws, fine sandpaper, wood glue, masking tape, rubber bumpers
Brass lid support and screws
Tools: Circular saw (or have the wood cut to size), drill, bits (1.5, 3.18, 3.81mm), phillips screwdriver
Mediumweight fabric and lining fabric
Spray adhesive and fabric glue
Here's how:
1. Sand wood surfaces smooth.
2. Draw lines for screw locations 1cm from lower edge of sides, front, and back pieces. Draw lines 1cm from side edges of front and back pieces. Starting 3.8cm in from each corner, mark screw locations on marked lines at about 15cm intervals.
3. Stand bottom piece on edge. Position one side piece so lower edges and sides are aligned to bottom piece. Use 3.18mm drill bit, drill holes 4.5cm deep at marked screw locations.
4. Remove side piece; redrill holes in side piece, using a 3.81mm bit. Apply wood glue to joint area.
5. Align pieces and secure with 5cm walloard screws.
Repeat steps above for other side.
6. Stand bottom and sides on end. Position front piece so side and bottom edges are aligned. Drill holes and secure with wood glue and screws as above.
7. Drill holes at lower corners first, then upper corners, then remaining holes. Repeat for back piece.
8. Apply spray adhesive to wrong side of fabric for outside of lid. Centre over top of lid, wrapping fabric around sides to bottom, forming mitred corners. Glue fabric in place at corners, using diluted fabric glue. Apply spray adhesive to wrong side of lining piece; affix to underside of lid. Seal raw edges of fabric with diluted glue.
Line and cover the chest; mitre and clip fabric at corners as necessary to wrap around to the inside of the chest.
9. Centre piano hinge on inside of lid, with hinge closed, so hinge edge is flush with plywood edge; tape in place. Predrill screw holes, using 1.5mm drill bit, beginning at ends. To prevent drilling through plywood, mark length of screws on drill brill, using masking tape and drill until tape reaches hinge.
Open hinge and attach using screws. Centre back edge of lid along back edge of chest, aligning edges and maintaining a small space between edges. Mark screw locations; remove lid. Predrill screw holes, using 1.5mm drill bit, beginning at ends. Attach hinge.
Position lid support and mark screw locations, using a pencil. Predrill screw holes and secure lid support using brass screws.
Apply rubber bumpers to the underside of the lid at front corners.
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