Designing and making your own wood tackle box is one way to organize your fishing lures and tools and have them exactly where you need them. It is also a productive way to spend a winter weekend when you would rather be fishing. You can make your own tackle box, including three compartments in the bottom of the box, with a removable shelf that rests on them. Design the compartments to your needs based on the equipment you have.
Examine your collection of lures and other items you use when fishing to estimate the size of your tackle box design.
Draw the dimensions on a piece of paper, making the box a rectangular shape. A typical box might be 7 inches high, 9 inches wide and 12 inches long. Keep the width of the wood in mind, as the outside dimensions are slightly larger than the inside. Decide what shape compartments you want for the bottom of the box and the removable shelf.
Cut six pieces of 3/4-inch plywood using a saber saw, two for the sides, two for the front and back, and two for the bottom and top, according to your size requirements. Use a metal square to ensure the pieces are straight and square.
Clamp the four sides of the box together with bar clamps. Where the ends of the pieces meet, drill two 1/4-inch holes, 1/2-inch deep, one an inch from the top and one an inch from the bottom. Remove the clamps.
Apply glue in the holes and along the edges of each side with a brush. Reassemble the pieces, and clamp them together. Cut eight 3/8-inch dowels to a length of 1/2 inch each. Brush the dowels with glue and put some glue in each hole, then insert the dowels into the holes. Tap them into place using a hammer. Wait for the glue to dry.
Place the bottom piece onto the four assembled sides. Measure and mark the middle of each edge. Hold the bottom firmly in place, then drill pilot holes into each corner, and one in the middle of each side, 1/2 inch deep. Screw the bottom to the sides using eight 1/2-inch screws. Tighten the screws until they are flush with the wood.
Place the lid on the box, flush to the edges. Measure 2 inches in from each end on the rear of the box and lid for the hinges. Screw them into place with the screws provided. Position the latch on the front of the box and screw it to the top of the lid and front of the box with the screws provided.
Screw a handle into the top of the lid with the screws provided with the handle.
Place three permanent partitions into the bottom of the box using pieces of 3/16-inch birch veneer, cut to fit the inside width of the box and 2 inches high. Place the partitions equidistant from each other and apply glue to the bottom and side edges. Finishing nails can be used to keep the partitions in place if desired.
Cut a piece of plywood to fit the inside dimensions of the box, less 1/8-inch for the length and width, to form a top shelf in the box. Put the shelf into the box to make sure it is a loose fit. File down the sides with a rasp if needed.
Cut grooves 1/4-inch deep and 1/2-inch wide into the top of the shelf to make compartments on the shelf. Then cut pieces of 3/16-inch birch veneer 1 or 2 inches high as desired, and glue them into the grooves.
Sand all edges and surfaces of your tackle box, then stain or paint it with a color of your choice.