Scratch Paper box build system

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Blog entry by Howard posted 09-18-2015 05:23 PM 1052 reads 0 times favorited 1 comment Add to Favorites Watch

Scratch Paper Boxes:

I use 1/4” plywood with a Maple finish. It has a non-wood center and Maple veneer on both sides. Available in my area thru Menards.
A 4’ x 8’ sheet cut properly will yield 48 boxes. I have included a scan of the instructions to myself for cutting down the 4 ‘ x 8’ sheet.

Finished Sizes: Cut the bottom FIRST…. 4 3/8” X 5 5/8”…. All other pieces are then fit to the bottom

Cut Out Section = 1 3/4” x 4 7/8”
Front of Box = 1 3/4” x 4 3/8”
Sides of Box = 1 3/4” x 5 7/8”
Top of Box = 2 1/4” x 4 7/8”
I have also included scans of the finished box to show you which sections overlap.

I cut all the pieces at least a 1/16” larger than needed… then as I glue them together (no nails are used), there is an overhang that I sand down with my bench top sander so that I end with a perfectly smooth edge. The order in which you glue them together does not matter as long as you sand them before adding the next piece. I use Elmer’s wood glue… cream colored. The bond will be stronger than the wood when dry.

At this point I prime and spray paint the boxes… Normally use “Flat” Black or White Flat spray paint. I have tried many other colors put matching the color when I need to touch up nicks is really tough.

Adding Pictures… You can add any pictures you want… personal or from the web.
You can make the picture larger than needed for each panel… glue in place… trim the extra with single edge razor blade….OR
I have started to create pictures just slightly smaller than needed for each section. I downsize the picture and then add a color coordinated frame to it using a FREE program found on the internet named FxFoto… does a marvelous job of dressing up the photo. I resize the photo after it is framed to exact size I want – using PictureIt! 7.0 from Microsoft.
The size of picture I am ending up with for each section is: Given in Inches with a 600dpi resolution:
Cut Out = 1.60×4.51 – Front = 1.80×4.52 – Sides 1.60×5.80 – Top 2.06×4.52
I have created boxes with straight and router edges…both are nice – just your personal preference.
After printing the pictures on High Quality Photo Paper, I let them dry for 1-2 hours, then I spray them with a clear finish and let this dry overnight. The reason for the finish is to protect the surface during the glue on process and when they are being used. After the finish is dry, I give the pictures 1-2 coats of Automotive wax for added protection.
I then cut out the pictures and glue them to the box using a craft glue/finish product named Mod Podge…
available at any craft store or Wal-Mart. I use the brush on type. I have tried other glues but this is my favorite as it allows me time to position the picture before it dries. NOTE: If you did not add the spray finish and auto wax to the picture…and you get some of this glue on the surface… the picture is ruined. Been there & done that several times before I learned to put the finish & wax on Before the glue then you can immediately wipe off any glue that gets on the picture with a damp cloth…careful not to wipe too hard!
After everything is dry… I go over the exposed edges with a Paint Pen (Medium Tip) … available in several colors at a craft store or Wal-Mart. This really helps to touch up any areas you may have nicked during the process. Then the final step is to add 1-2 more coats of Auto Wax and you have a box that will stay nice looking for Years!
That’s it… Actually a lot easier than all these instructions sound. I just gave you the extra details to save you some mistakes when you start building some.

-- Life Member of: USA + NRA + USMC = Semper Fi to all three.

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105 posts in 1846 days

#1 posted 09-18-2015 09:19 PM

Update…. Lately I have been using Gloss Lacquer by Watco to spray the picture (2-3 coats) and then to spray the final box when all is glued and dry. Only one coat of automotive wax after that. Gives a nice finish with a little less work overall. Can not testify about how it will hold up over several years but I assume it should be just fine.

-- Life Member of: USA + NRA + USMC = Semper Fi to all three.

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