Toy Box with Lid Support

Cut list

Board layout. Each row is one board, cut left to right, with the remainder hatched. Dark lines are saw cuts, about ⅛″ wide.

Build it

1. 
   01

   Cut the pieces

   Cut every piece from the plywood. Ask the store to rip the sheet into strips first if it won't fit in your car:

   • A Front and back, two at 17¼″ × 32″
   • B Ends, two at 14½″ × 17¼″
   • C Bottom, one at 14½″ × 30½″
   • D Lid, one at 16½″ × 33″
2. 
   02

   Cut the hand holds and air holes

   On each end (B), mark a hand hold 4½″ long and 1¼″ tall, centered across the end, its center 3″ below the top edge. Drill a 1¼″ hole at each end of the slot and cut between them with a jigsaw.

   On the front and back (A), drill two 1″ air holes, 6″ in from each end and 2½″ below the top edge.

   Watch outThe air holes matter. A child who climbs in and gets shut in needs air. Holes in the front and in the ends stay open even when the back is against a wall.
3. 
   03

   Build the box

   Stand the two ends (B) between the front and back (A), flush at the top, bottom and outside faces. Glue each joint, drill pilot holes and drive three 1⅝″ screws through the front and back into each end.

   TipMeasure the two diagonals across the top: when they match, the box is square. Let the glue set before you move on.
4. 
   04

   Add the bottom

   Turn the box over and fit the bottom (C) inside, flush with the bottom edges. Glue it and screw through the front, back and ends into its edges.

5. 
   05

   Round every edge and sand

   Round over every edge and corner of the front and back (A), the ends (B), the hand holds and the lid (D) with a ¼″ roundover bit or a sanding block, until there are no sharp corners anywhere. Sand everything with 120 then 180 grit.

6. 
   06

   Hinge the lid

   Lay the lid (D) on the box, flush at the back, overhanging ½″ at the front and both ends. Screw a piano hinge along the back: one leaf to the back of the box, the other to the back edge of the lid.

7. 
   07

   Add the lid supports

   Screw a toy box lid support to the inside of each end (B) and to the underside of the lid (D), following the maker's instructions for this lid's weight, about 9 lb. The supports have to hold the lid open in any position, not just fully open.

   Test it: lift the lid partway and let go. It must stay where you left it, at every height. If it drifts down, tighten or adjust the supports until it doesn't.

   Watch outA lid that falls can hit a child's head or neck. Never use a plain hinge with no support, and never add a latch, hasp or lock.
8. 
   08

   Finish

   Paint with a water-based paint that's labeled safe for toys, inside and out, and let it cure for a few days. Add felt pads under the corners.

   Watch outCheck the lid supports every few months and tighten their screws: some loosen with use. Keep the air holes clear.