Build a toy box

One sheet of plywood, a lid that stays up on its own, and a floor you can see again.

This fits in a car

About 80 lb of materials. Comfortably inside what a car carries (200 lb), so any shopper can take it. ⚠️ 3 items on the list have no weight on file, so the real load is a little heavier than this.

Before you start

Sand every edge and corner round. Plywood only, never pressure-treated wood, on anything kids handle. The lid supports are the important part: a lid that slams can trap fingers or a head, so no latch, and keep the hand-hold slots open for air. Put heavy toys low so it cannot tip.

What to buy — untick anything you have

Lumber

1 Birch plywood, 3/4 in, 4×8 sheetAsk the cut station for: two 30×18 in, two 16×18 in, one 30×16 in, and one 31×17 in for the lid.

Hardware

2 Toy box lid support, safety typeMust say it holds the lid in any open position. A plain hinge alone is not safe on a toy box.
1 Piano hinge, 30 in
1 box of wood screws, 1-5/8 in
1 bottle of wood glue

Supplies

1 roll of iron-on birch edge banding
1 pack of sandpaper, 120 and 220 grit

Paint

1 tub of wood filler
1 quart of water-based primer
1 quart of low-VOC enamel paintWhatever color the kid picked. Low or zero VOC.

Tools — already ticked off, since most people have them

Tools

1 Cordless drill· most people have this
1 Jigsaw· most people have this
1 pair of bar clamps· most people have this
1 Random orbit sander· most people have this
1 Old clothes iron· most people have this

It lands in the shopping form, where you can edit anything and say what you think each thing costs. Nothing is ordered until you send it.

How it goes · about a weekend · some experience

Cut a hand-hold slot near the top of each end panel with the jigsaw. It doubles as an air gap.
Glue and screw the front, back and ends around the bottom panel, clamping as you go and checking it is square.
Iron the edge banding onto the raw plywood edges, fill the screw holes, and round over every corner with the sander.
Prime and paint the box and lid, and let it dry for a full day before it gets used.
Fit the lid with the piano hinge, then fit the two lid supports and check the lid stays open wherever you let go of it.