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Attach the reinforcements: Press each plywood strip firmly against the marked locations on the interior of the box. Hold them in place with clamps or use screws to secure them to the interior walls. Make sure to pre-drill pilot holes to prevent splitting. After staining, you will have rough wood that needs sealed and smoothed down again. I usually use polyurethane to seal my stained wood. If you’re using a light stain or no stain at all, you may want to use polycrylic instead, as urethane does yellow slightly over time. To give your plywood box a polished and professional look, it’s important to sand and finish the surfaces. Sanding will smoothen any rough edges or imperfections, while finishing will enhance the aesthetics and protect the wood. Follow these steps for sanding and finishing your plywood box:
In this step, we will focus on installing the bottom panel of the plywood box. The bottom panel adds stability and provides a solid foundation for your storage items. Follow these instructions to install the bottom panel: Now that you’re ready with all the necessary supplies, let’s move on to the first step: measuring and cutting the plywood panels. Step 1: Measuring and Cutting the Plywood Panels Sandpaper— 80 and 120, and 320 grit (120 is for sanding after box assembly, when a palm sander is handy. I always use adhesive sandpaper when using my palm sander.) When using the jig saw in this step, always err for a smaller hole rather than a larger hole. You can use sandpaper to make your jig saw cuts better match the hole saw cuts in step three.
Because I was using IKEA Billy bookcase units with about 14″ width openings, I was restricted to a box size that would fit inside each little cubby. Allow the finish to cure: Once you have applied the desired number of coats, allow the finish to cure according to the manufacturer’s instructions. This may take a few hours or several days, depending on the type of finish used. Step One: Cut the pieces needed for the sides and bottom of your boxes. See the section above about determining the sizes you need. With your completed plywood box, you can now enjoy the benefits of a well-organized space. The durability and versatility of the plywood construction will ensure that your storage needs are met for years to come.
The bottom of my boxes were left unpainted, because I didn’t want paint scraping against shelves as the boxes are slid in and out. I had considered waxing the bottoms of the boxes so they’d slide more easily, but in the end I decided to use felt pads instead. The problem with this solution was that I couldn’t find any boxes I liked that were the exact size I needed. So I decided to make my own custom plywood storage boxes.Circular Saw or Table Saw: Either of these saws will be required for cutting the plywood panels to size. Apply the finish: Using a brush or a cloth, apply the chosen finish in smooth and even strokes, following the grain of the wood. Allow the first coat to dry completely before applying additional coats if necessary. Follow the recommended drying time between each coat.
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