I cut my long boards 19 1/8 inches long.
I cut my short boards 16 1/4 inches long.
I cut a 3/4 inch rabbet 3/8 deep in the board.
It makes a box 19 7/8 inches long by 16 1/4 wide and however deep you need the boxes.
For the handles I use a 1 1/2 x 3 inch cup wheel (it has carbide steel tips) using my drill press to cut the handles.
The wheel is actually designed to buff tires.
It's the safest way I've seen to make the handles.
I have a jig I clamp to the drill press table and just insert my boards and make a couple of swipes on the wheel,
A perfect handle everytime.
I glue the rabbets and brad nail it together.
I use a tri-square inside the box in opposite corners to square it up.
My approach is very similar to Capt.'s, with a few small differences...
- My short boards are 13 3/4" b/c I do 8 frame equipment (I do the single 3/4" rabbet, 3/8ths deep on those)
- I glue with Titebond III and shoot with six or seven 1 1/4" staples on each corner.
- I use the radial arm saw and a jig to do my hand holds, as described in the
I've seen a video on the method capt describes for his handholds, it does a VERY nice job....I just don't have convenient access to a drill press, plus I didn't have the bit, nor the patience to wait for it to come in when I was in box building mold. However, I'm pleased with the results of my hand holds.
Concerning the OP, out of curiosity I decided to compare price from my local Lowe's and Home Depot, as well as a local lumber yard. On 1x8x8's and 1x12x8's Lowe's and Home Depot have the identical price...to the Penny! Coincidence? I think not!
Lowe's and Home Depot 1x8x8 $8.47
described by Lowe's as Kiln dried whiteboard and by Home Depot as #2 Kiln dried Whiteboard or better.
#2 Pine from my local Mom and Pop Lumber yard: 1x8x8 $3.80
Lowe's and Home Depot 1x12x8 (same descriptions) $14.18
Local Mom and Pop....No #2, only #3 1x12x8 $6.76
Wow! That's quite a difference....wonder how the quality varies? Might be worth exploring. Has anyone used the #3 to make boxes?