Things You'll Need
Instructions
Put two pieces of 3/4-by-15-by-18-inch glued wood panels on a worktable. Measure in from one 18-inch side and make a mark at 2 inches. Move the measuring tape over a little and make another mark at 2-inches. Repeat this action on the remaining three sides. Put the straightedge on the marks and draw lines parallel to the sides of the panel. Repeat this on the other wood panel as well.
Drill a 5/8-inch hole near one of the corners of the lines. Insert the blade of the jigsaw and cut on the lines. Repeat this action with the other glued wood panel. Sand the cut edges with a sanding block and 100-grit sandpaper.
Make marks from all four sides as before, but this time make them at 1-inch and draw lines as before. Drill pilot holes on the lines in each of the four corners and 3-inches apart between the corners with the 1/16-inch drill bit. Drill countersink holes on the pilot holes with the countersink bit. These holes hide the screws when they are installed.
Place these two pieces on top of the other two pieces of the same size. Align the sides and trace the cutout pattern onto the other boards. Remove the two pieces and, with a small paintbrush, brush glue between the sides and the lines drawn. Put the cutout pieces on the glue with the countersink holes facing up.
Secure the cutout pieces to the other two pieces with the wood screws. Clean up excess glue with a damp cloth. Place the two pieces on top of each other so the cutouts are on the inside of the gun storage box. Stand the box on one 18-inch side and install the hinges with the supplied screws.
Place the lock in the desired location on the side opposite the hinges. Hold it in place and install it with the screws supplied. Spray the foam adhesive inside the cutouts and install the foam.