Laser Cut Game Card Box With Internal Hinges

15 years ago I designed a box to hold CD's and makes it easy to flip through them. Now someones project to make a game card box inspired me to use that mechanism on a laser cut box for game cards.

We are kind of addicted to playing "werewolf" and created our own deck for it. This would be a great box to hold that deck. (that explains the wolf theme)

Materials:

• 4 mm plywood (25 x 50 cm)

Tools:

• lasercutter
• sand paper
• glue
• brush or cloth
• clamps
• optional: paint, wax or oil

The most work was designing the box. I was amazed that the hinge mechanism actually works.

I used 'Gravit Designer' to draw the box, so I added both the original Gravit file and a PDF.

The red-lines are cutting lines and everything black is for engraving.

• Lasercut the parts.
• Sand smooth the sides of the moving parts.
• The four curved parts also need to be sanded slightly thinner for easy sliding.

• Start with the bottom.
• Glue the two inner sides in.
• Add the inner back.
• Glue on the outer back.
• Clamp everything together.
• Use a wet brush or cloth to remove excessive glue.

• Glue the 3 non moving parts on the side.
• Put the 2 moving parts in between for accurate spacing.
• Clamp the not moving glued parts.
• Repeat for the other side.
• Glue in the outer sides. (make sure that the moving parts are in before glueing the outer sides)
• Clamp.

• Glue the inner front door in the nick on the hinges.
• Make sure that it is all the way down.
• Glue the outer front door on top.
• Clamp together.
• Remove excess glue.
• Close the front door while drying for correct alignment.

• Glue the two inner pieces of the lid to the hinges.
• Glue the four outer sides around the inner part. (the front and back are the same, but the sides can be put on backwards.)
• Glue the top on.
• Clamp everything together.

I had to sand a bevel to the inner lip on the front door to make it easier to close the lid. I also sanded the laser marks from all sides.

If you want you can wax, oil, paint or lacquer the box.

Now just add the cards.

(there is a notch for a coin in the back, because we sometimes flip a coin while playing werewolf)

I think it came out great.