Locate the four 8 x 15-inch pieces of plywood and glue a rail to one side
of two of them. If you countersink the screw holes, make sure they are
on the outside. Align them flush with the sides and end. Apply glue and
clamp in place. Next, install three #6 flathead 3/4-inch wood screws in the
predrilled holes. Remove the clamps. The screws will hold it in place until
the glue cures.
Cut four 2-inch lengths of rail from the extra piece I instructed you to cut,
and glue them in as shown in the photo. Center them 3-1/2 inches from
each end. These will be the backing for the screws in the hinge and chest
latch. You will need to cut down the thickness so they will fit flush with the
sides of the top.
Step #5 Step #8
With the top and bottom rails installed and complete, remove 1/4 inch from
each side of them. This will make the case size 15 x 15-1/2 inches. The 15-
1/2-inch length will be the front and back of the case. Mark the base and
top “front” and “back” as shown.
Locate the other 15 x 15-inch piece with rails. I hope you cut 1/4 inch off of
each side. This will be the top. Glue on the sides and install the screws.
Align the sides flush with the top and ends. When complete, it should
match up with the base if your measurements were accurate.
Step #4 Step #7
Stack the four 8 x 15-inch sides and tape them together. Locate and stack
the 1-1/2-inch sides for the top and tape them together. Lay out the holes
for the screws. Make them 1/4-inch from the side and 2 inches in from each
end, with one in the center. Drill a 7/32-inch hole at all locations. Because
you are using a flathead screw, you will have to countersink the holes for
the screw head. I made mine slightly deeper and used filler to make the
Glue the two sides with the rails to the base. Align and install the screws
in each of them. Be sure to glue these two sides onto the base where you
removed the 1/4 inch, making it 15 inches across with the sides installed.
Cut a scrap piece 15 inches long and tack it to the top, making sure that
there are 15 inches at the top end. Now glue on the side, align, and install
the screws. Glue on the other side using the same method. This completes
the case’s base.
Step #3 Step #6
HM3 Model Aviation DECEMBER 2015