Scouting Patrol Box

This sturdy box can hold everything that a 10 person scouting patrol needs for a campout. Space is divided to provide an area for a two burner stove, washing bowl, pots, pans, propane lantern, lighter,dish soap,and utensils.

The box is made from a single 8'x4' sheet of 1/2" plywood

Parts List

Lumber

1/2" ACX Exterior Plywood. 4' x 8' sheet
3/4" x 3/4" Poplar - 123 linear inches

Hardware

Strap Hinges 4” - National N127-969 - 2 off
Hasp 3.25” Safety Hasp - National V30 N102-277 - 1 off
Handles Spring Flex Cabinet Handle Zinc - Penn-Elcom H7154Z - 2 off
Chain - 22”
T Nuts 8-32 Grainger 1XGH2 - 20 off
T Nuts 10-32 - Grainger 1XGH4 - 16 off
Machine Screws 8-32 x 0.5” - Grainger 2AB31 - 20 off
Round Head Screws 10-32 x 0.5” - Grainger 1ZE21 - 16 off
Slide Bolt Spring Snap 3 3/8” - Grainger 4GGJ3 - 1 off
Wood Screws 8 x 1" - about 35
Carriage bolts 1/4" x 1" - 2 off
Nyloc Nut - 2 off
Para Cord - 10"

Tools & Equipment

Table Saw (or ask your lumber supplier to cut the lumber to size)
Router with 1/2" bit
Clamps - lots of them
Screwdriver
Electric Drill & various drill bits

Cut Out the Pieces From the 8'x4' Sheet of 1/2" (12mm) Plywood

Cut out the pieces per the attached plan

Cut the Corner Supports and Bottom Rails to Length

Cut the 3/4" poplar into 15.25" lengths - 4 required
Cut the 3/4" poplar into 30.75" lengths - 2 required

Use the Router to Add the Necessary Dados

The following pieces all need dados, rebates or slots

Left Side
Right Side
Front
Rear
Divider 1
Divider 2
Divider 3

For the dados and rebates, set the bit height to half way into the plywood (about 6mm deep)

The slots are obviously cut all the way through.

To make it easy, I marked the wood to show where the slots were to be made. And then made a simple fence to guide the router. It would be easier to cut the rebates using a router table.

Note that the top, bottom and Divider 4 need no routing