Make your own outdoor storage box

Measure your plywood following the cut list above. Position and clamp a straight edge to help guide your saw, then cut the panels out. Make sure you wear your safety gear.

Mark and rule lines every 75mm from the centre of each panel on the side panels.

Use a 45-degree groove router bit to add grooves along the lines you marked in the previous step. Position and clamp a straight edge to help guide your router. 

These grooves significantly enhance the overall look of the box, so are definitely worth doing.

Use 80 grit sandpaper to sand smooth the grooves.  Wipe off the sanding dust.

Mark and drill pilot holes using a ⅛ countersink drill bit. Assemble the sides to form the box structure using glue and 45mm stainless steel screws, then glue and screw the bottom panel.

Measure and cut the batten pieces from decking timber according to the cut list.

Measure 20mm in from each corner, then mark and drill pilot holes 70mm and 300mm up from the bottom.

Glue and screw two corner battens to each corner of the box using 32mm stainless steel screws – this provides the sturdy structure to the box. Chamfer each cut edge as you go. Attach the screws from the inside of the box.

Glue and screw the side battens in place.

Drill pilot holes in the 20mm timber pieces, then screw into the edges of the top plywood piece to conceal the raw edge – this piece will become the lid of the storage box.

Glue and clamp the top batten pieces to the lid piece, then flip it over and use screws to secure the battens from the underside.

Measure 500mm in from the short edge of the top, then cut to split the lid into two pieces. This will make the box more practical and easier to open.

Install the divider piece inside the box 500mm in from the short edge (to match with the smaller lid piece). Secure support pieces and divider battens with screws.

Use a 25mm chisel to carve out a rebate for each hinge. Drill pilot holes then secure the hinges with screws. 

The hinges will be removed before painting the box.

Use Resene EzyFill to fill any visible holes, then sand the whole storage box to prepare it for painting. Wipe away all the dust after sanding. 

Whenever you’re sanding or cleaning off sanding dust make sure you have your safety gear on.

Pour your Resene Quick Dry into a paint tray, then use a roller to apply it to all surfaces, inside and out. Use a paintbrush to reach the grooves and batten edges effectively. Once dry, lightly sand with 120 grit sandpaper and wipe away all the sanding dust.

Stir your Resene Lustacryl well, then pour into a clean paint tray. Apply two coats to the storage box using a roller and paintbrush – Jae used the colour Resene Bokara Grey.

Allow dry time between coats.

On the base, attach low profile heavy duty locking castors to each corner.

Flip the box over and reinstall the hinges to join the two lid pieces to the main box.

Add a gas strut to each lid to help prevent slamming.

Time to stow all your gear and move the box to a place where you can access it easily. 

Placing some outdoor cushions on the top is a great idea to provide extra seating and add another purpose to your new piece.