Materials list

Corrugated Cardboard Boxes
Hobby Knife
Ruler with metal edge
Triangle
pencil and eraser (for marking cardboard)
white glue
2 Straight pins for hinge (optional)

Please note the direction of the corrugated flutes...
note the dashed lines and arrows on the pattern below.

Thick cardboard makes the strongest box, and shows a thicker edge (with the wavy core showing). For best results, make your notches at least 3/8 inch from the edge of the cardboard. Use a sharp cutting blade (like a #11 Exacto) and don't try to cut all the way through on the first stroke. Each cut may take 3 or more passes before you have cut all the way through. When cutting against the direction of the corrugation, be aware that the blade may stop and start as it cuts through the hills and valleys of the core. Be careful!

An option--use cardboard pieces with printing on them. Logos, numbers, seals and "Fragile" graphics all can add a little extra to your box. You might even try a clean pizza box lid!

1. Cut out the cardboard using the pattern below as a guide. Make the box any size you like. If you wish to use this pattern, print it out at 200%, your finished box will measure 6" X 3" X 4-7/8". Front and Back pieces measure 6"x 3", Sides measure 4-7/8" X 3". The Bottom and lid size will vary depending on the thickness of your cardboard. This box was created with 3/16 inch thick cardboard. Bottom measured approx. 6"X 3-3/8", Lid 4-11/16" X 3-3/8"
   

2. Cut notches one half the height of the box. The long side of the notch should start 1/2" away from the edge of the piece. The width of the notch should be the same thickness as your cardboard. Front/ Back are notched on the bottom half and the Sides are notched on the top half.
   

3. Cut slots in Sides for Bottom to slide into. The long edge of the slot should be 1/2" from the bottom edge of the box.
   

4. As you work, test fit the pieces together, starting with the Front, Back and Sides. Then slide the Bottom into the slots.
   

5. Determine the Lid position by measuring 1/2" from the Inside top edge and adding the thickness of your cardboard. Draw a pencil line for reference on the Inside Front and Back pieces.
   

6. With the box unassembled, glue a narrow strip of scrap cardboard below the pencil line on the Inside Front and Back pieces. This is a ledge for the Lid to rest on. Glue the flat side to the cardboard, allowing the wavy corrugated edge to be seen from the top view. Make sure these strips don't extend over the notch areas.
   

7. Assemble box, Front and Back to the Sides first. Slide in the bottom. Drop on the lid. Add a 1/2" wide Strip of scrap cardboard the length of the Lid for a handle. Glue it "on edge" to the Lid, off center if you are going to hinge the lid. Center it if you want a free floating Lid. Add as many strips as you like to customize your design.
   

8. Create a hinge using the 2 Stick Pins. With the lid in place, open the box and push the Pins through the sides of the box from the outside into the edge of the lid. You may have to do a little experimentation here to get the placement right. Try opening and closing the lid to find the best position for the pins.
   

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