Rockler Woodworking And Hardware
Build this Winning
Poker Chip Box

Rockler's Pre-formed Box Molding makes this project a snap. Plus you can easily modify the plan to be a jewelry or music box.

Poker Chip Box

1) Cut the front, back and sides of 4' walnut small box molding to length.

2) Mortise back for hinges. With the lid cut to size mortise for hinges.

3) Cut dados for holding partitions in the front, sides and long dividers. Note that the dados are cut 1/8" deep in the front and side pieces, and 1/16" deep in the long dividers.

4) Sand internal parts of sides, front, back, partitions and bottom. Test-fit pieces together and hold together with large rubber bands or web clamps. Test-fit blocks and partitions in same manner. Sand grooves necessary for an easy installation as the partitions will be slid into place after the front, back, sides and bottom are glued together.

5) Apply an even coat of wood glue to mitered ends of the front, sides and back. Assemble these pieces around bottom. (Note: Do not glue bottom as it is better to let it free-float so that it can adjust to environmental changes.) Clamp box together with web clamps, rubber bands, etc. until glue dries. Remove excess glue with damp rag while glue is still wet.

Divider With Notch
Poker Chip Box Parts
Chip Block
Drill 1" diameter holes, then cut the block to its finished size.

Chip  Box Top View

6)
Dividers and blocks can now be inserted into assembled box. These do not need to be glued in but a drop or two of glue can be added to each piece to help keep in place if desired.

7) Sand box and lid smooth, and finish all pieces as desired.

8) Fasten hinges into mortised back piece. Drilling of pilot holes for screws is recommended. Mark and drill pilot holes and attach hinges to top. Add optional solid brass jewelry box feet for an added touch.

Plan requires approx. 35'' of molding

Items available from Rockler
Woodworking and Hardware
qty
4' walnut small box molding #26582 (1)
Jewelry box feet (optional)   #9856 (1)
Jewelry box stop hinges #70391 (1)
Rockler poly-gel finish (optional) #29585 (1)
Web Clamp #60545 (1)
Titebond Glue #50187 (1)
Self Centering Bits # 5911 (1)
1/4'' Walnut * #14613 (10)
Walnut 4-3/4'' width, 3/4'' thickness *
#11437 (20)
(Walnut requires cutting, gluing & machining to size)
Material List
1 Front and Back (1) 7/8" x 2-13/16" x 9-3/16"
2 Sides (2) 7/8" x 2-13/16" x 7-11/16"
3 Bottom (1) 1/4" x 6-3/8" x 7-7/8"
4 Top (1) 3/4" x 7-5/8" x 9-1/4"
5 Long Dividers (2) 1/4" x 2-1/16" x 7-3/4"
6 Front Divider (1) 1/4" x 2-1/16" x 2-9/16"
7 Center Divider (1) 1/4" x 2-1/16" x 1-1/16"
8 Card Blocks (2) 1-3/16" x 2-3/8" x 3-5/8"
9 Dice Blocks (2) 1-1/16" x 1-5/16" x 3-5/8"
10 Chip Block (1) 1-1/2" x 2-3/16" x 7-9/16"
11 Hinges (2) 1-1/2" Brass
12 Feet (2) (optional) Brass


*
Please type this quantity into box when ordering. Qty of 10 is approximately equal to one square foot. Qty 20 for 11437 sold by lineal inch.


© 2002 Rockler Woodworking and Hardware