BUILD IT WITH CARDBOARD

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Next, use a screwdriver to chisel out the inside face veneer and the corrugations from the areas indicated in the drawing ... leaving a single veneer hinge. These are spaces between two fold lines where the cardboard will have to turn back 180° . . . either onto itself (1/4" space) or over an adjoining tab for assembly (3/8" space).

Along all the other fold lines (which will require finished angles of only 90°), use the capped end of the Bic pen to smooth down the knife cuts. Now, bend the panels—toward the inside of your future box-along each fold line . . . creasing it with your hands as you go.

PUT IT ALL TOGETHER

To assemble your storage chest, take the body section and lay it flat on the table as shown in the plans, with the inside to—be facing up. Fold the right—end panel (the back) and the left—end panel (a side) 180° in upon the other two panels, so that the side panel overlaps the glue tab on the back (marked "A" in the drawing). Lift the side panel enough to apply some glue on the tab beneath it, and put some books on top of the joint to hold it until it dries.

While you're waiting for the adhesive to set, you can assemble the top of the box. To do so, fold the glue tabs marked "B" and "C" up 90", then do the same with the panels marked "D" and "E". Apply some glue to both sides of "B" and "C", and fold the front panel marked "F" up against the tabs and "G" down over them. Finally, put a large paper clamp at each end of the front panel, to hold it in place until it dries.

When the body is ready to be worked with again, square it up . . . fold the four tabs marked "H" 90° to the inside place some glue on them . . . drop the bottom piece in place down through the inside of the box . . . and weight it down with books until the connection is secure. Then apply glue to the inside of the body's upper tabs, marked "I", fold them down flat (180°) inside the box, and told them in place with large paper clamps while they dry.

When all the glued surfaces have set, case the side of your ballpoint pen to burnish down the edges of the panels which were folded 180° . . . to give the borders a neat appearance. Now, take a 10" piece of brown paper tape, crease it lengthwise down the center, wet it, and apply it over the glued corner of the body to cover the corrugated edge of the side panel.

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