Jewelry Box

The actual finished item. This is a very simple project and ideal as a gift for Mom. Only adult woodcrafters should use a drill or drill press to make the holes in this item. The project is constructed from scraps. The box sides are made from a 2-1/2" tall casement or rail molding, the bottom from a small piece of 1/8" masonite, and the top from a 3/4" scrap.
	Simply click on each of the drawings to open, or download, a larger version. First, cut the 1/8" groove along the bottom of the molding exactly 1-7/8" from the top edge (see drawing above). You can use either a router or a circular bladed saw (with a 1/8" wide blade) but it must be an accurate and true cut. Next, cut out the four box sides, with 45o mitered corners, making sure the inner dimension of the cuts are at exactly 3-1/2". The outer length will vary, with the molding thickness (as indicated in the drawings above and left). Now, create the corner feet by removing the curve as indicated above. This cut is 1/2" deep.
Cut a piece of 3/4" thick stock to 4" by 4" for the lid. Make a cut 11/32" deep and 1/4" tall along all four sides of the lid (as indicated in the drawing to the right) then use your disc or belt sander to generously round the corners. Use a 1/4" round-over router bit along the top edges of the lid to finish shaping it (as indicated in the drawing to the right).
	Cut a piece of flocking, or good quality felt, to 3-5/16" by 3-5/16" for the inside of the lid and another to 7-1/2" by 7-1/2" for the inside of the box. Remove the 1-3/4" squares from each corner as indicated in the drawing to the left. Use an exacto knife and a metal straight edge to score the back side of the flocking, along each side, to allow it to bend more easily and to guide the placement of the bends. Locate a suitable small knob for the lid. trim the dowel insert on the knob to 1/2" if it is longer than 1/2".
The Jr Woodcrafter will need a hand drill and the proper size bit(s). The holes need to be the proper size for the knob you have selected. It may be best to drill a pilot hole first (about 1/8"). You may wish to drill the hole in the lid and not allow the Junior Woodcrafter to drill in order to ensure a better looking final project. (Delete steps 1-3 of the directions.) Now all your Junior Woodcrafter needs is the six wood pieces, the knob, the two pieces of flocking, two wide rubber bands, a roll of masking tape, the directions, a hand drill, drill bit(s), one sheet of 150 grit sandpaper, a really cool workshop apron small enough for kids, and safety goggles.
Construction.
1. Locate the center of the top of the lid by using a straight edge to draw light pencil lines from corner to corner (as sown in the drawing to the right). 2. Drill a 1/2" deep hole in the center by using the smaller drill bit (1/8"). Be careful to NOT drill all the way through the lid. 3. Sand all the inner edges of the sides to a smooth finish. 4. Apply glue to one end of one side then stand it upright and glue it to another side to form a n L.
5. Apply glue to one end of another side then stand it upright and glue it to the last side to form another L. 7. Apply a light bead of glue into the grooves in the bottom of each side. 8. Slide the bottom piece (smooth side up) into the groove formed by the first two sides. 9. Apply glue to the two exposed ends of one L. 10. Slide the other L into place with the bottom fitting into the groove.
11. Place the two rubber bands around the sides to hold everything in place while it dries. 12. Apply a thin layer of glue to the back of the remaining flocking, fold it along the precut lines, and slip it into the box being careful to not spread glue on the top edges. Wipe off any excess glue. 13. Use short pieces of the masking tape to keep all the top edges of the flocking flat against the inner surfaces. 14. Turn the box upside-down to keep all the top edges flush. 15. Check the corners to make sure all corner edges are meeting flush. 16. Sand all surfaces of the lid to a smooth finish. 17. Apply a small amount of glue into the hole in the lid and insert the knob into the hole. Wipe off any excess glue. 18. Apply a thin layer of glue to the back of the flocking for the lid and place it on the inner surface. 19. Place the lid flat on the table and weight it down with a book to make sure the flocking glues flat to the lid. 20. Once all glue has dried, place a large piece of sandpaper on a flat surface and sand the feet level. 14. Sand all remaining surfaces and edges to remove all sharp corners and smooth all surfaces. You may wish to finish the entire box by spraying on a clear protective finish.

*********** WARNING***********
Read my page on safety before building this item.