A standard courier service (DPD, TNT etc.) is usually used to deliver smaller items with a weight limit of 30kg and a maximum length of 1.5m per parcel. A delivery can comprise multiple parcels with no limit on total weight. Measure the dimensions: Determine the size of the box you want to build. Consider the height, width, and depth based on your storage needs and available space. Use a measuring tape to accurately measure each dimension. When creating my built-in Billy bookcase unit, I wondered if should put cabinet doors on the lower section to hide away less attractive items, such as office supplies and most of our children’s books. In the end, I decided matching boxes would be a nice look. Plus, boxes would offer portability to the items inside. Step One: Cut the pieces needed for the sides and bottom of your boxes. See the section above about determining the sizes you need.

Step Five: Carefully remove the duct tape from the joints after the nails are in place. Peel slowly and toward the edge of your wood panels, not away from the edge, or you may pull apart bits of the plywood in the process. After dry or wet sanding your primer, you may have to do some touch-up priming in spots where you sanded away the primer. No need to resand these spots, though, unless they’re substantial areas. Lastly, apply two or three coats of paint and your boxes are finished! 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. 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.

Multifunctional Ply Boxes

To make 11 boxes I used two full sheets of 1/4″ plywood plus about 1/2 of a sheet of 1/2″ plywood. (The 1/2″ sheet of plywood was leftover from this fold-away dollhouse project.) Wire brads (I used 1/2″ brads to nail through 1/4″ plywood and 1″ brads to nail through 1/2″ plywood.) Throughout the process, we discussed the materials and tools needed, how to measure and cut the plywood panels, assemble the box, add reinforcements, install the bottom panel, and finish the surfaces. These steps ensure that your plywood box is not only structurally sound but also aesthetically appealing.

Step Four: Assemble the pieces of your box with wood glue* at all the joints, taped together with duct tape until you’ve added nails. The box won’t hold together super well with duct tape, so you’ll need to work gingerly as you begin to hammer in brads through the joints. 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 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: 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.But if you’re just painting the boxes, then a general smoothing down of the surface is good enough. Apply wood glue: Apply a thin and even layer of wood glue along the edges of one of the side panels. This will help create a strong bond between the panels. By adding reinforcements to your plywood box, you are reinforcing the structure and ensuring its strength and durability. This step is especially important for larger boxes or if you plan to store heavy items. With the reinforcements in place, your box is now ready for the next step: installing the bottom panel. Step 5: Installing the Bottom Panel

Allow the assembly to dry: Leave the box in a well-ventilated area and allow the wood glue to dry completely according to the manufacturer’s recommendations. This may take several hours to overnight.Measure and cut the bottom panel: Measure the dimensions of the opening at the bottom of the box. Using these measurements, cut the plywood panel to fit snugly inside the box. 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. Be sure to remove any seeping wood glue before it dries! It is very difficult to sand away dried wood glue. And if you plan to stain your boxes, dried glue will repel stain and ruin your finish. Some people choose to wipe away wet wood glue with a damp rag (that’s me!), while others may use a chisel or blade to scrape it away as it begins to harden. Building your own plywood box for modular DIY storage is a practical and cost-effective solution to help you organize your space. Whether you need extra storage in your garage, basement, or living area, a plywood box can be customized to fit your specific needs and can be easily modified or expanded in the future. Circular Saw or Table Saw: Either of these saws will be required for cutting the plywood panels to size.

Measure and mark the reinforcement locations: Use a measuring tape to determine where you will place the reinforcements inside the box. Mark these locations on the interior walls with a pencil. I chose to make my boxes 1″ more narrow than the shelving opening to give myself and my children wiggle room when returning each box to its space. I also made the height of the boxes 3/4″ shorter than the opening. I’m happy with how this sizing worked out for me. Determine Lumber Needed Sand the edges: After cutting the plywood panels, lightly sand the edges to remove any roughness or splinters. This will not only enhance the appearance of the box but also make it safer to handle. I cut 1″ wide strips from these felt blankets and put them on either side of the bottoms of the boxes. They slide super easily now.Apply wood filler (if needed): If there are any visible gaps or holes in the plywood, you can use wood filler to fill them in. Follow the instructions on the wood filler product and allow it to dry completely before proceeding. Sand the surfaces: Use sandpaper or a power sander to gently sand all the exposed surfaces of the plywood box. Start with a coarse grit sandpaper (around 80 or 100) and gradually move to finer grit (around 150 or 180). Sand along the grain of the wood to avoid scratching the surface. Pay extra attention to the corners and edges to ensure a smooth finish. 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. Before we dive into the construction process, let’s first gather all the necessary materials and tools. Here’s what you’ll need: