Can someone make me a wood box?

[Berties]

I don't have the workshop or skill required do it, although if someone was watching over me correcting me I could. So could someone build a box for me?

It's for a bicycle trailer, to fit on a Carry Freedom large Y Frame (remove supplied base board) I'm not sure which material and thickness is best, ply? 9mm? I would like it strong but don't want it over engineered to the point it weighs a ton. But don't want 1mm balsa wood either.

Must be local (Staffs, Cheshire area)

I have 8 eye bolts and want these spaced to allow bungee cords to be used.
80cm length, 62cm width, 50cm height. With overlapping lid with lockable clasp.
Fixing points for lights
Dovetail joints.

Rated maximum carrying weight of the Y frame is 90kg.

although if there were ready made templates, should be able to do it...

Got a circular saw, router, router bits, jigsaw, manual planer, drill, wood and metal drill bits.

 

[Benchwayze]

Hi Bert,

I am a bit far away, so can't help with the making.

I suggest you use 18mm exterior grade plywood. As you say you don't have the skills, go to a sawmill who provide a cutting service.
Buy the timber from them and provide them a simple drawing of the dimensions of each piece. (Six pieces for your box, and four pieces for the drop over frame of the lid.

Get a single, Kreg pocket hole jig/ and drill bit set from Rutlands,

Here's a link. The first item is the one you want.

http://www.rutlands.co.uk/cgi-bin/psPro ... &submit=Go

Have a look on Youtube, and search for Kreg. There are tons of Vids that will show you how the jig works. All you need is an electric drill of some sort, and you should be able to make this yourself.

With a good exterior glue, the pocket-hole screws should be strong enough for this job.

HTH
John

 

[Berties]

Can you screw into plywood along the layers? I thought it would split. So thought about putting a piece of wood in the corner, and screw. So only screws through the plywood, not across.

There is a local timber merchant who can cut the pieces to size.

Thought about using metal corner braces (bottom corners, and L braces for top)

 

[jumps]

can't see that an individual build is going to save you anything on the vast choice of purpose built accessories for this

http://www.carryfreedom.com/Y-Frame.html#2

equally you will inevitably end up adding (a lot) of weight over 'plastic' solutions to get any strength

if I was doing this I would be using 6mm ply with epoxy sheathing - joints wouldn't be 'woodworked' they would be stitched with copper wire and then epoxy etc but it wouldn't be particularly cheap

Both of the suggestions you have now posted will work with larger thickness ply - but the weight will be significant.

 

[Benchwayze]

Berties,

Yes your sketch-up would work and with it you can use all kinds of bracing, which can be bought from places like Screwfix.com
A bit of Googling for hardware supplies will help.

Pocket-hole screws don't screw into the edges of the plywood, as they are driven in at an angle and go into 'side-grain'. Along with glue, and some angle brackets, it should be OK. That said, not knowing much about bicycle trailers, I wouldn't ignore the advice about buying something ready made for the job.

In common with most woodworkers here, I make stuff for the enjoyment of it, and because I can save a bit of cash. However, subtract the money spent on tools and equipment, and the time of course, and I might not be so much 'in-pocket' as I think...

So there are times when I buy 'off the shelf' because it makes economic sense, or SWIMBO wants it post haste! .

Regards
John

 

[Berties]

I've got a spare bit of plywood 18mm, so making a replacement base board (removing supplied one) and fitting two 60cm x 40cm plastic boxes. Fitting some eyelet bolts through the box and baseboard, with the eyelet underneath (can attach bungees and also doubles up as a locking point) Not costing me much needed the eyebolts.. Got two heavy duty boxes with lids.


Since bungees would go under and over the edge, I would like to round the edges. Got a router, and this set of bits.
screwfix direct 15010

I guess it's possible to round both edges over and make edge U shape? Set the beating smack in the middle and do both sides? That way it won't start further.
Probably use 1/4" rounded edge. Problem with buying ready made box, I can't find exactly the right size, either lots of space ie 45cm box, or way to big.

I have no problem making a board, lol if I can't do that pretty useless. Box with dovetail/finger joints bit of my league and probably make a bodge wasting a board up, costly mistake. However I reckon should be able to do it, if I just cut out a glued out template ontop of the wood.