How to build a wooden gun box with a removable tray for firearm storage

Building a Wooden Gun Box with a Removable Tray: A DIY Guide

Hey there, fellow firearm enthusiasts! Let's talk about something really satisfying: building a custom wooden gun box with a handy removable tray. It's a project that combines the joy of woodworking with the practicality of safe firearm storage. Plus, you can personalize it to fit your exact needs and style.

I'm not going to lie, building this box requires some basic woodworking skills and tools, but trust me, it's not as daunting as it sounds. I'll walk you through the steps in a way that's easy to follow, even if you're a beginner.

Materials and Tools

Before we dive in, let's gather everything we need. Here's a list of materials and tools, but feel free to adjust based on your preferred wood type, dimensions, and finish:

Materials

• Wood for the box (e.g., 1/2-inch plywood, pine, oak, maple) - I recommend using plywood for the base and sides for durability and stability. You can use solid wood for the top for a beautiful look, or if you're feeling fancy, use a contrasting wood for the lid and tray.
• Wood for the tray (e.g., 1/4-inch plywood, pine) - Go for a thinner plywood for the tray to make it easier to lift and maneuver.
• Wood glue - I prefer a good quality wood glue like Titebond.
• Screws - Choose screws that are long enough to secure the pieces together but not so long that they poke through the other side. I usually use 1 1/2" screws for the box and 1" for the tray.
• Finish (e.g., stain, paint, polyurethane) - Choose your favorite finish for the box and tray. I enjoy a nice natural stain on my wood, but you can go for a bold paint or a glossy polyurethane, depending on your taste.
• Hinges - Get sturdy hinges that match the size of your box. For a small box, you might only need two hinges, but larger boxes may require three or four.
• Magnetic catches or latches - These will help secure the lid of your box.
• Optional: Drawer slides - If you want to make a more elaborate tray, consider using drawer slides for smooth movement.

Tools

• Measuring tape
• Pencil
• Saw (circular saw, jigsaw, hand saw) - Choose the saw that you feel most comfortable using for cutting the wood to size.
• Drill
• Screwdriver
• Clamps
• Sandpaper - You'll need various grits (80, 120, 220) for smoothing out the wood and preparing it for finishing.
• Finishing tools - You might need brushes, rags, or a spray gun for applying the finish.

Building the Gun Box

Okay, time to get our hands dirty! Here's how to build the box itself, step-by-step:

Step 1: Cut the Wood

Start by cutting the wood for the box to the size you want. For example, you might need two pieces of plywood for the sides, two pieces for the front and back, and one piece for the bottom. Measure carefully, mark your cuts, and then saw the wood precisely. Make sure the sides and front/back are the same height.

If you want to create a little lip around the top of the box, you'll need to cut the front and back pieces a little longer to create a small overhang.

Step 2: Assemble the Box

Once you have your pieces cut, it's time to assemble the box. You can use a technique called "butt joints" where you simply glue and screw the pieces together. This is a simple and sturdy method. Here's how:

• Apply wood glue along the edges that will be joined.
• Clamp the pieces together tightly to ensure a good bond.
• Pre-drill holes (slightly smaller than your screw size) to prevent the wood from splitting.
• Secure the pieces together with screws, placing them evenly along the edges.

Repeat this process for all the sides of the box, making sure they are aligned and flush. Let the glue dry completely before moving on.

Step 3: Attach the Bottom

With the sides assembled, you're ready to attach the bottom. This is similar to attaching the sides, but ensure that you are attaching it flush with the bottom edges of the sides. Again, glue, clamp, pre-drill, and screw the bottom to the box.

Step 4: Cut and Attach the Lid

Now, it's time to make the lid. If you want a simple lid, just cut a piece of wood to the same size as the top of the box.

For a more secure lid, you can create a rabbet (a groove) around the edge of the lid. This is a technique where you create a recess on the underside of the lid that fits snugly over the edges of the box. This creates a very tight fit and keeps the lid from warping.

To create a rabbet, use a router with a rabbeting bit or a hand router if you have one. If not, you can also use a hand saw and chisel to create a shallow groove around the lid.

After the lid is cut, you can attach the hinges. Drill pilot holes for the hinges on the lid and box, and then secure them with screws.

Step 5: Add the Magnetic Catches

To keep the lid closed, you'll need some magnetic catches. Mark where you want to place them on the box and lid. Pre-drill pilot holes for the screws and then install the catches. Be sure that you align the magnet and latch properly.

Building the Removable Tray

Now, for the exciting part: the removable tray! This is the element that makes your gun box super functional. Here's how to build it:

Step 1: Measure and Cut the Tray

Measure the inside dimensions of your box (length and width), and then decide how deep you want the tray to be. You want to make sure that the tray fits snugly inside the box without too much wiggle room. Cut your wood for the tray to these dimensions.

Step 2: Assemble the Tray

Assemble the tray using the same technique as the box: glue, clamp, pre-drill, and screw the pieces together. Be sure to use screws that are short enough not to poke through the bottom of the tray.

Step 3: Optional: Add Drawer Slides

If you want a really smooth-sliding tray, you can install drawer slides. Just make sure you get the right size and type of drawer slides for your box and tray dimensions. Measure carefully and follow the instructions that come with the drawer slides.

Finishing the Box and Tray

Almost there! It's time to give your box and tray a beautiful finish. Here's how to do it:

Step 1: Sanding

Sand the entire surface of the box and tray using sandpaper of different grits (starting with a coarse grit like 80 and working your way to a fine grit like 220). This will smooth out any rough edges, create a uniform surface, and prepare the wood for finishing.

Step 2: Applying the Finish

Now it's time to get creative with your finish. You can stain, paint, or seal the box and tray.

• Staining: Apply the stain evenly to the wood. If using a water-based stain, use a rag to apply and wipe off excess stain. If using an oil-based stain, use a brush to apply and allow it to soak in for a bit before wiping off the excess. Let the stain dry completely before moving on to the next step.
• Painting: Choose a paint that is appropriate for wood, and apply it with a brush or roller. Allow each coat to dry completely before adding another layer. You can add as many layers as you need to achieve your desired coverage.
• Sealing: If you want to protect your finish, you can seal it with a polyurethane or a varnish. Apply the sealant evenly with a brush, roller, or spray gun. Follow the manufacturer's instructions for drying times.

Tips for Success

Here are some helpful tips to make your woodworking project even more successful:

• Start with high-quality wood: This will ensure that your box is sturdy and lasts for years.
• Use clamps: Clamping the pieces together while the glue dries will ensure a tight and secure bond.
• Pre-drill holes: This will prevent the wood from splitting when you screw it together.
• Sand thoroughly: A smooth surface will make your finish look much better.
• Choose the right finish: Consider the style and use of the box when deciding on the finish.
• Don't rush the process: Take your time and let the glue dry completely before moving on to the next step. This will give you a much better result.

Conclusion

Congratulations! You've now built a beautiful and functional wooden gun box with a removable tray. This is a great way to store your firearms safely, securely, and stylishly. Plus, you can customize it to fit your specific needs and preferences.

Remember, building a gun box isn't just about the final product, it's also about the journey of creating something with your own hands. Have fun with the process, be patient, and enjoy the satisfaction of crafting something unique.