Author: CMN

Step by step guide showing how to build a box to store shooters powder.

You will need
1, A router and a 6mm router cutter to cut the groves and hinge housings.
2, A drill and bits for the screw holes
3, A saw unless you buy the wood cut to size.
4. General hand and marking out tools.
A reasonable knowledge of woodworking skills is assumed..

50p
to cover cost of reproduction.

Partition length 536mm

Partitions are 6mm thick plywood

560mm

Each Square is 100mm

Partition length 218mm

Box to store Shooters powder in (as per new regulations.)
Lid is to be hinges and held down with a hasp and staple fitted with a security padlock. An intumescent strip is recommended to be fitted to ensure a good seal between the lid and the box.
All exposed metal on the inside of the box should be covered with a glued wooden liner not less than 6mm thick.
Lid not shown on plan
(Shooters powder = smokeless powder and/or black powder.)
This drawing assumes no exposed metal on the inside of the box, allow extra length if you are going bolt through the external ply frame.
All dimensions in millimetres.
3rd angle projection.
Errors and omissions accepted.
Author C M Nicholls. (R2)

Side length 206mm

242mm

Box must be screwed together

Height 30% more than tallest container (300mm+)

18mm thick plywood

Cutting list

Two pieces of 18 mm thick ply for front and back
Length 560 mm
Height 30% more than tallest container (300 mm +)

Two pieces of 18 mm thick ply for left and right hand side
Length 206 mm
Height 30% more than tallest container

Two pieces of 18 mm thick ply for Top and Bottom
Length 560 mm
Width 242 mm

One piece of 6mm thick ply for long partition
Length 536 mm
Height 30% more than tallest container (300 mm +)

Four pieces of 6 mm thick ply for short partitions
Length 218 mm
Height 30% more than tallest container (300 mm +)

This is a photo of the authors box. He made his box 336 mm high, all sides and partitions were cut 300 mm high. This may not be tall enough for you, please check what height you need before you cut any timber

Ironmongery and timber, (All items in brackets are as used by author to make his box.)
1 pair of hinges (50mm Steel butt hinges)
1 hasp and staple.
28 screws to hold box frame together (2 1/2” x 10 csk pozi)
9 screws for holding hasp and staple on ( 3/4” x 8 csk star drive security screws.)
8 screw to hold hinges on ( 4 off 1 1/2” x 6 csk pozi + 4 off 3/4” x 6 csk pozi)
Intumescent strip is available from “Complete fire protection ltd, Unit 2, Ferry steps industrial estate, Albert road, St Philips, Bristol, BS2 0XW, Tel 0117 971 1917” ask for FP102 and ask them to make it without the brush strip. It is 1 mm thick and sticky backed, you need one and a half strips to fit the box. It is made in 1050mm long strips which are 25 mm wide.
18 mm shuttering ply (2440 x 1220 sheet is enough for 3 boxes)
6 mm ply (2440 x 1220 sheet is enough for 6 boxes)

Top and bottoms

Front and backs

Sides

2440 mm x 1220 x 18 mm ply marked out for 3 boxes

Short partitions

Long partitions

2440 mm x 610 mm x 6 mm ply marked out for 3 boxes

Choose ONE only

Short partitions

Long partitions

1220 mm x 1220 mm x 6 mm ply marked out for 3 boxes

100

100

100

100

100

1

2

Equal

18 mm strip with the first and last hole 30 mm in from the edge

4 slots 6 mm Wide by 6 mm Deep

A slot 6 mm Wide by 6 mm Deep

Take the Front and Back pieces of wood and find the middle. From the middle mark, measure 50 mm each side and mark, from that mark measure 6 mm and mark. Repeat this again so you have four 6 mm slots marked out. Cut the 4 slots 6 mm deep. Mark off 18 mm strip from each end, mark and drill 4 clearance holes for the screws in the centre of that strip. Countersink holes on the others side to the slots.

Take the Left and Right hand sides and find the middle. From the middle mark, measure 3 mm each side and mark, Cut the slot 6 mm deep

3

106

100

100

100

106

4

106 mm

106 mm

Take the long partition pieces of wood and find the middle. From the middle mark, measure 50 mm each side and mark, from that mark measure 6 mm and mark the slot. Repeat this again so you have four 6 mm slots marked out. Each slot should be 5 mm longer than half way. Cut the 4 slots all the way through the wood.

Take the four short partition pieces of wood and find the middle of each piece. From the middle mark, measure 3 mm each side and mark the slots, Each slot should be 5 mm longer than half way. Cut the slot all the way through the wood.

5

95 mm

6

Equal

Equal

Equal

Equal

18 mm strip with the First and last hole 30 mm in from the edge

Note hole off set to avoid slot cut in side piece

Take the piece of wood that is to be the top, measure in 95 mm and mark around the hinges. Cut out enough wood for the hinges to fit flush with the surface of the wood.
Attach with screws

on the bottom piece of wood, mark out holes and drill clearance holes then countersink for screws.

7

8

Take the front, back and 2 sides. Using the predrilled holes in the front and back as a guide, drill pilot holes for the screws and put main frame together. You might find it useful to hold it together with a few panel pins while you drill the pilot holes. Screws about 65 mm long work well.

Take the bottom. Using the predrilled holes as a guide, drill pilot holes for the screws and put bottom on. You might find it useful to hold it together with a few panel pins while you drill the pilot holes. Screws about 65 mm long work well.

9

10

Assemble partitions and slip in to the box, a dab of wood glue here and there will help to hold them in

Mark out hinges on the main body of the box and cut wood away to allow hinges to fit flush with the surface of the wood.

11

12

Fit intumescent strip to the lid

Fit hasp and staple,

Note small blocks of wood glued to inside to cover metal of the hinges if there is not 6 mm of wood left when hinge housing was cut. Use off cuts of ply from partitions. Shown much larger than real life for emphasis.