My son asked if I could make some varying sized boxes that he could use as props for photography, to sit things on or stage things to be photographed. I bought a 2420 x 1200mm sheet of CD grade Non Structual 12mm Plywood and had it cut into 4 600 x 1200mm pieces at Bunnings so that I could bring them home in the car. I drew a rough plan for three boxes in sizes of 600mm x 300mm x 300mm, 600mm x 300mm x 150mm and lastly 600mm x 300mm x 75mm.
Using my table saw I cut the Tops and Bottoms, Side and End panels from the smaller sheets of Plywood. I also found a couple 140mm x 19mm pine boards laying around that I cut up into 19mm x 19mm strips that I would use as framework for the boxes.
I used an old single bed base slat and brad nailed a strip of 12mm plywood to the edge and used this as a jig/guide to position then glue and brad nail the framework pieces to the top and bottom box pieces.
I used my CNC Router to carve some handle cutouts in the end pieces and used a 25mm Forstner Drill bit for finger holes in the smallest box.
Then used a 1/4" roundover bit on the Router Table to smooth the handle cutouts.
Then it was simply a matter of assembling all the pieces with glue and brad nails.
This would have been a lot nicer using Marine Grade Plywood but I couldn't justify the difference in cost. CD Grade plywood has 1 good face and 1 rough face but even the good face required lots of sanding to get a smooth finish. Once the boxes were assembled and left for a couple hours for the glue to dry I then rounded over all the corners and edges on the router table as well. I sanded them fully starting with 80 Grit, then 120 Grit and finally 240 Grit using Random Orbital Disk Sanders then a 1/3 sheet finish orbital sander. I will fill the nail holes with putty then give one final sanding so they are ready for painting. I think he will paint them in a Matt Black or Chalk Board Paint.