Rolling Toy Box
Make playtime and cleanup a little easier with this organizational storage unit.
Instructions:
General: Cut and label the parts as needed, using the Cut List and Cutting Diagram as guides and adjusting for fit.
1 Create the box assembly.
a. To make the hand holes in the (01) ends, first drill two 1 1/2-inch holes 6 inches apart, 1 inch down from the top edge, and centered horizontally. Then cut out the waste using a jigsaw.
b. Position the (02) sides flush with the outside edges of the (01) ends as shown in Figure 1. Attach using glue and #17 x 1 1/4-inch brads.
c. Check for square, and adjust as needed.
d. Using glue and #17 x 1 1/4-inch brads, attach the (03) bottom as shown in Figure 2.
e. To make the hand hole in the (04) handle, first drill two 1 1/2-inch holes 6 inches apart, 1 1/2 inches down from the top edge, and centered horizontally. Then cut out the waste using a jigsaw.
f. Scribe and cut the arc on the (04) handle as shown in Figure 3.
g. Center the (04) handle in the box assembly, and attach using glue and #17 x 1 1/4-inch brads.
2 Attach the caster blocks and trim.
a. For each corner of the box assembly, attach two (05) caster blocks together using glue and #18 x 1-inch brads. Allow the glue to dry.
b. Position a caster-block assembly flush with the edges at each corner of the (03) bottom as shown in Figure 4. Attach using glue and #17 x 1 1/4-inch brads. Allow the glue to dry.
c. Scribe to fit and miter cut the (06) long top trim, (07) short top trim, (08) end edge trim, (09) end bottom trim, (10) side edge trim, and (11) side bottom trim as shown in Figure 5. Note: The (08) end edge trim and the (10) side edge trim extend slightly below the upper caster blocks. Attach the trim parts using glue and #18 x 1-inch brads.
d. Attach the casters to the caster-block assemblies and box assembly using 1 5/8-inch screws.
3 Apply finishing touches.
a. Fill any nail holes. Sand any rough edges or sharp corners. Sand the (08) end edge trim, (10) side edge trim, (06) long top trim, and (07) short top trim where these parts meet.
b. Prime and paint.
Cut List
| # |
PART NAME |
QTY. |
MATERIAL |
SIZE (in inches) |
| 01 |
ends |
2 |
plywood |
1/2 x 24 x 17 1/2 |
| 02 |
sides |
2 |
plywood |
1/2 x 35 x 17 1/2 |
| 03 |
bottom |
1 |
plywood |
1/2 x 24 x 36 |
| 04 |
handle |
1 |
plywood |
1/2 x 23 x 25 1/2 |
| 05 |
caster blocks |
8 |
plywood |
1/2 x 3 x 3 |
| 06 |
long top trim |
2 |
moulding |
1/2 x 11/16 x 36 3/8* |
| 07 |
short top trim |
2 |
moulding |
1/2 x 11/16 x 24 3/8* |
| 08 |
end edge trim |
4 |
moulding |
1/2 x 11/16 x 18 1/8* |
| 09 |
end bottom trim |
2 |
moulding |
1/2 x 11/16 x 24 3/8*
|
| 10 |
side edge trim |
4 |
moulding |
1/2 x 11/16 x 18 1/8*
|
| 11 |
side bottom trim |
2 |
moulding |
1/2 x 11/16 x 36 3/8*
|
* Scribe to fit.
Finished Dimensions:
Height: 29 inches
Depth: 25 inches
Width: 37 inches