Hexagonal Stacking - sort of - Box

Video HERE

Some time ago I bought a small, rather sad-looking cardboard box that opened to reveal some rather small drawers/shelves. I have recently been experimenting with angled cuts on my scroll saw and this seemed the perfect opportunity to combine both ideas.

I have drawn up rough plans, and I will add the measurements that I used to make this 5-shelf hexagonal stacker at a later date (when I can find them in the stack of finished projects!). The construction of this box was rather piece-meal, as I dealt with problems that occurred along the way so I didn't take proper notes. These are instructions for the ideal construction technique.

You Will Need:
Scroll Saw with a sturdy blade*
4mm Plywood
Templates (Cutting list below)
Sandpaper
Strong wood glue +/ Contact Adhesive
Masking Tape +/ Large Elastic Bands
Craft Knife and Scissors
Thick paper**
Ribbon
Hinges and clasps
Lining fabric or felt
PVC or Leather

*If you have access to a CNC then this is rather simple, if not you can manage with a table saw, or even a coping saw, although you'll have to ensure you can maintain the angles, or try and sand back the edges.
**Something thicker than copier paper is ideal for covering a multitude of errors whilst minimizing the added thickness to each drawer.

Cutting List
[TBA, apologies]

Method:

1. Securely fix the templates to your ply, cover with tape if you want.
2. Adjust your scroll saw blade to 30 degrees and make the angled cuts*, you will find it easier to cut the shelf sides in longer strips before breaking them down.
3. Re-adjust your blade to 90 degrees and make the rest of the cuts.
4. Fit the shelves together, glue and clamp with tape or elastic bands.
5. Check the angles of the box sides, adjust with sandpaper as required, then tape together and roll up the sides to check they fit correctly.**
6. Sand the shelves flat, then cover with the paper.***
7. Cover the lid and the inside of the box sides with paper and slit open the shelf slots - no need to cut the paper back completely.
8. Hinge the inside of the box sides with ribbon, then cover the outside with PVC and cover the edges with more ribbon.****
9. Glue the shelves into their slots - making sure they each sit at right angles to the sides - , clamping tightly until set.
10. Line each shelf - if you haven't already.
11. Screw in the lid hinges and side clasps.*****
12. Trim with decorative paper, finished with varnish.

*You cannot use a fence on a scroll saw, so this relies on your own ability to hold the line. If in doubt cut slightly wide and sand to the line as required.
**If you are concerned about the fitting of the shelves I would suggest making the outer wall first, then use the internal measurements to adjust the shelf plans to something around 4-5mm smaller.
***You can line them here as it's easier to get proper access before they're fixed in place.
****Contact adhesive would have been a better choice here, otherwise use your best glue, be generous, clamp well and allow everything to dry completely before moving on.
*****You will probably need to slightly bend the latch tongue on the bottom clasp so that it will form around the sides.

Considering the difficulties that I had with maintaining the angles and fit here, I actually rather like this box. It is definitely on my list of projects to repeat.