You will need:
- 22mm plywood or Supawood
- Piano 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), Philips screwdriver
- Medium-weight fabric and lining fabric
- Spray adhesive and fabric glue
Cutting directions:
1 x front / 1 x back 38 x 84cm
2 x side 38 x 49.8cm
1 x lid 54.8 x 86.5cm
1 x bottom - measurement from front to back equal to 49.8cm. The measurement of the bottom from side to side is equal to 84cm minus twice the thickness of the plywood.
Here's how:
1. Sand wood surfaces smooth. 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.
2. 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.
3. Remove side piece; re drill holes in side piece, using a 3.81mm bit. Apply wood glue to joint area. Align pieces and secure with 5cm wallboard screws. Repeat steps above for other side. 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. Drill holes at lower corners first, then upper corners, then remaining holes. Repeat for back piece.
4. 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 (see pic left). 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.
5. Line and cover the chest; mitre and clip fabric at corners as necessary to wrap around to the inside of the chest.
6. Centre piano hinge on inside of lid, with hinge closed, so hinge edge is flush with plywood edge; tape in place. Pre drill screw holes, using 1.5mm drill bit, beginning at ends. To prevent drilling through plywood, mark length of screws on drill bit, using masking tape and drill until tape reaches hinge.
7. 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. Pre drill screw holes, using 1.5mm drill bit, beginning at ends. Attach hinge.
8. Position lid support and mark screw locations, using a pencil. Pre drill screw holes and secure lid support using brass screws.
9. Apply rubber bumpers to the underside of the lid at front corners.
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