While Ron was up in his attic looking for Christmas tree lights, he ran across his old childhood train set and came up with a great holiday idea. He decided to start his own family tradition by building a special holiday train storage box that unfolds into a train platform and Christmas tree stand. When the holidays are over, the train cars and track will go back inside safe and sound, all ready for the next holiday season.
Click Here For a list of what
you will need in order to complete this project.
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View, download and print Ron's Train Case Drawings
1. Cut wood
Cut 1 X 4 pine to length to create the frame of the box and cut ¼" bead board for the outside skins. You can get these materials at any home improvement center and chances are they'll even cut the bead board for you. Ron's box dimensions are 3' x 3', but you can make your box any size you'd like.
2. Assembly
The first step is to apply a bead of woodworking glue to the top edge of the framing wood and then set the bead board right on top.
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| The box is designed to look like an old packing crate so you might consider enhancing the look by using nails with large heads to attach the bead board to the sides. If you prefer to use a staple gun, the job will go faster.
After the first half of the case is assembled, build another one just like it. Together, the two parts will form the storage box. |
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| Since the storage box will also serve as a support for the Christmas tree, you will need to add additional bracing inside. These are also secured in place with glue and nails.
After the supports are glued along the edge, use a tri-square to make sure that they are perfectly vertical.
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3. Piano hinge
After both halves of the box are fully assembled, secure them permanently with a piano hinge. Firmly clamp the two box halves together. After cutting the hinge to length, lay it across the joint between the two box halves. Use a self-centering bit to drill pilot holes in each of the hinge holes.
Then go back and drive in all of the screws. Be careful not to over tighten the tiny fasteners. This can cause the threads to become stripped. |
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4. Customize compartments
After the box is fully assembled, take several train pieces and lay them inside the box to get an idea of how to arrange the storage compartments for a customized fit. A separate compartment for each of the individual cars will protect them and keep them from banging against each other.
Rigid foam insulation is an excellent cushion material that is inexpensive, easy to work with, and readily available at most home improvement centers. To create several 3-inch wide strips, simply mark the foam and then use a very sharp blade to score the material. (This takes about two passes.) Once the surface has been scored, break the foam in half. The foam should break with a clean edge. |
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| Use an adhesive that is designed for foam board and apply it to the foam with a serpentine pattern.
Begin by outlining the first section with the foam strips, and then use the train pieces to determine the size and shape of each section within each compartment.
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5. Felt lining
To make the foam more durable, to give the train added protection, and to make this whole case look more attractive, it is a good idea to line the compartments with felt.
Mix a little water into white glue to thin it out, and then brush the glue on the inside of the compartment. Cut the felt to fit each inside edge of the compartment and place the felt in place and allow it to dry thoroughly.
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6. Panels
Create panels from bead board to provide a separate enclosure for each compartment. Drill two holes in each panel to make removal easier. This will keep the train and accessories snug when the box is closed. Use small squares of Velcro to secure these panels in place.
The box should have plenty of extra space for storing additional train and accessory pieces that will surely be added to the set in holiday seasons to come. |
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| Ron is hoping that this new addition to his holiday collection will last for many Christmases to come. In fact, perhaps his children will want to use it for their Christmas tree someday.
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