- 1). Use the scroll saw to cut a 5-by-1-inch rectangular hand-hold out of the centers of the two 15-by-2-inch pieces of plywood, 1/2 inch from the top edge. This will be the ends of the tray. Slowly but firmly turn the wood around the blade to get the desired cut.
- 2). Sand all of the plywood pieces, smoothing out any rough patches, rounding off the edges, paying particular attention to the inside edges of the hand-hold.
- 3). Lay the 18-by-15-inch base piece of plywood flat on your work surface. Place the two pieces with the hand holds on either end so that the 15-inch sides of those pieces match up to the 15-inch sides of the base. Square off the pieces, then glue and clamp in place; let dry.
- 4). Position the remaining two 20-by-2-inch pieces of plywood along the 18-inch side of the base. The edges of the ends of the tray will meet up with the corners of the 20-by-2-inch pieces to form the complete sides of the tray. Square off, glue and clamp in place; let dry.
- 5). Hammer a nail every 3/4 inch through the joints of the tray, along the bottom of the sides into the base, and through the sides of the 20-by-2-inch pieces into the abutting ends of the 15-by-2 inch ends.
- 6). Fill the nail holes with wood putty, let dry, then sand over the putty-filled areas for a smooth and even finish.
- 7). Paint or varnish the box, following the manufacturer's recommended drying times. Apply two or three coats as desired.
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