This puzzle is designed by Erhan ubukcuoglu 2012Istanbul /TURKEY

Copyrights Erhan ubukcuolu 2012

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Toothpick Box

Finally I completed my twin lock box with hidden keys. I call this box Toothpick Box. Mechanic of the box is exactly same with Twin Lock Box. For this box I made side panels longer for hiding wooden keys. On each side of the box there are five small hole (5 mm diameter) For opening the box you must configure wooden keys by pushing them. Because of production clearances there are a small clearance on box cover. That makes easier to find the cover but it's not important. Because finding the cover dont help to open the box.

I made this box from padauk. They call some time Blood wood I was expecting an orange color. But its red. I am not sure is that true color or the wood is exposed to sun light on seller shop. Because on woodworker sites they say this wood becomes darker when exposed to sun light.This is my first puzzle with padauk. All workshop, my clothes and me became red because of sanding dust It paint everything like an oil pastel. This is a little bigger box (82x92x150 mm) Dimensions are planned for less scrap from my material.

Box Material List

Pcs Name Dimensions (mm) Quantity (pcs)Wooden keys

Wooden keys 10x10x67 10Left and Right Frame

Slider support columns 25x10x70 4Frame base and top 10x10x80 4Left and right panel 6x80x70 2Front and back panel 6x82x150 2Bottom panel 6x80x150 1

Cover Material List

Pcs Name Dimensions (mm) Quantity (pcs)Box cover

Slider body 30x10x70 2Cover plate 6x80x150 1Wooden pins D3x10 10Wedges for corners 20x20x30 2

How to make toothpick puzzle box

This puzzle has three main section1. Wooden keys2. Box3. Box cover

I started to make this puzzle by making wooden keys. After box and box cover.

For material I advise to use hard woods like beech or mahogany etc. for keys and frames.

Making wooden keys

There are 10 keys. Some of them are left hand and some of them are right hand. Left hand keys are in open position when they are pushed to the left and right hand keys are in open position when they are pushed to the rightI made 5 right hand and 5 left hand key. You can make any combination that you like.

This picture show only left and right keys. NOT IN SCALE. See drawing for key dimensions.Total dimension of each key 10 x 10 x 67 mm

On the photo below you can see two method for making the keys. The keys at the bottom of the photo is made with my firs method. ( with clear color made of beech) For making them after cutting the slot with a jewelery hand saw, I drilled two holes and connected them with a knife. This method is difficult for making the keys

I developed an alternative method. The keys on the top of the photo (made from mahogany and with dark color) are easy to make. You can cut the slots easily with any method that you like. I cut them by using a hand mitre saw and a jewelery saw.

In this box design keys with two position works fine and I think enough tricky for fun and keeping content from curious eyes. But if you like something more tricky you can make add some keys with a third position. You can open this box only when this key is at the center position

Making the frame

The picture show the box construction before mounting front and back panels.Prepare the material given by the material list. Make a grove 5x5x10 mm to the middle of the frame top pieces.

When making assembly I used small paper pieces for giving necessary clearances.

I assembled first left and right sides. After I mounted them on base plate.For front and back panels there are a planned dimension. But that change related to material thickness. For a best fit, I prefer cut them after mounting left and right panels by measuring real dimension.

Making the box cover

The box cover is a flat wood pieces as seen on the photo at left. Two cover sliders are glued on this wood pieces. For fortify the construction two triangular wood pieces glued to the bottom of that sliders as seen on the photo.

Making two cover sliders

Wooden pins are cut to 10 mm length. Drill holes 3 mm diameter and 6 mm depth. After fixing wooden pins, you will have 4 mm length wooden pins. Distance between pin centers is 10 mm and very precise. For easy marking pin locations you can use a compass.

Fixing cover sliders to correct position

Gluing sliders to correct position on cover precisely is tricky. I put small cardboard pieces under both slider. They became higher than the box height. And it's became easy to fix them in correct position

The inside view of the box