Box Joints and Toy Boxes

dusty · Post by **dusty** » Thu Aug 23, 2012 6:34 pm

I got four toy boxes to build. I've built toy boxes before that did not hold up. I would like for these to out live me.

To accomplish this, I am contemplating quality 1/2" plywood and box joints.

I am looking for opinions on box joints in plywood corners. Will this work or do I need to build with real wood to have a chance?

fjimp · Post by **fjimp** » Thu Aug 23, 2012 7:32 pm

Dusty,

I have used 1/2" Baltic Birch Plywood and box joints for drawers in the shop. Although someone on our forum pointed out that was a poor idea, I must say they have taken a beating for several years and held up very well. Yes I will use the Baltic birch plywood again with box joints. Jim

joedw00 · Post by **joedw00** » Thu Aug 23, 2012 10:00 pm

I have been wondering about this too. I have been asked to build some patrol boxes for our troop, and was thinking about using box joints, but I would have to use plywood so it would hold up to all the abuse they will get.

fjimp · Post by **fjimp** » Thu Aug 23, 2012 10:33 pm

fjimp wrote:Dusty,

I have used 1/2" Baltic Birch Plywood and box joints for drawers in the shop. Although someone on our forum pointed out that was a poor idea, I must say they have taken a beating for several years and held up very well. Yes I will use the Baltic birch plywood again with box joints. Jim

I should add to my prior post that my first drawer of this type is a deep drawer where I keep a belt sander and several other heavy items. I just emptied and inspected it. No question it is as solid today as when built seven or eight years ago. Jim

charlese · Post by **charlese** » Fri Aug 24, 2012 1:30 am

dusty wrote:I got four toy boxes to build. I've built toy boxes before that did not hold up. I would like for these to out live me.

To accomplish this, I am contemplating quality 1/2" plywood and box joints.

I am looking for opinions on box joints in plywood corners. Will this work or do I need to build with real wood to have a chance?

I have never made box joints using plywood, but I think they should hold up well if using baltic birch (as above) or a good grade of plywood of mixed species as long as there are no voids in the sheets.

One issue you may find using plywood is tearing out of the edges (top ply) of the fingers. Since you use a router, make sure the boards are backed up on both sides before cutting. The only way you'll find out is to give it a try.

Best wishes!

bffulgham · Post by **bffulgham** » Fri Aug 24, 2012 8:41 am

Yep, ditto things said above. I've built a couple of drawer units out of baltic birch, both the outer cabinet and drawers using half-blind dovetails for the drawers and butt joints for the outer shell. Used daily for several years and holding up well. You will need to use backers on both sides of the ply to minimize tear-out. I used TiteBond II for both projects.

I also built a smallish sea chest for my first grandson using BB with the ends set in rabbets (added support and to mostly hide the ply edges on the outside of the box). It has survived the family pirate hauling/dragging it around for the last 3 years quite well.
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