Here are the directions for assembling the Large (42" wide) Sea Chest. If you have the smaller (22" wide) version, the process is identical.

• phillips head screw driver (#1 and #2 blades)
• mallet or hammer
• block of soft wood
• chisel (maybe)
• wood glue
• finish: stain, tung oil, lacquer, or varnish and application tools.

• 1 top
• 2 sides
• 1 front
• 1 back
• 4 or 5 bottom sections
• 2 side trim
• 1 front trim with carving
• 1 back trim
• 1 bottom of drawer
• 1 side of drawer with notches in corners
• 1 top of drawer
• 2 beckets
• 2 hinges

• 42 #8 x 1¼" screws for trim and handles (extras included)
• 20 #6 x 1" screws for bottom (extras included)
• 6 short screws for top hinges (for lid, painted black)
• 6 long screws for top hinges (for back panel, painted black)
• drawer lid handle
• 42 plugs (extras included)

Note: Pieces have numbers or letters stamped in the edges or sides so they can be matched with like-marked pieces.

Consider applying the finish before assembly because it’s easier to work-up a nice finish. Remember to finish the ends of the dovetails, but not the "insides" where you’ll glue them.

As the chest is made of mahogany, you have a variety of finishing methods at your disposal. You could create a furniture-like finish using paste wood filler for the pores, remove that with burlap, then stain, lacquer, wet sand, and buff-out to a mirror finish with rottenstone. Or simply stain and tung oil. We did one with paste wood filler, 50/50 mix of Minwax brand red mahogany and dark walnut stains (outside only), then a couple of coats of gloss tung oil, then a couple of coats of satin tung oil, then rubbed down with 0000 steel wool, then lemon oil. THEN we assembled. You can see pictures of that on our Store site: http://www.woodenboatstore.com.

Ensure you have all the parts as listed above. Call us at 1.800.273.SHIP (7447) if parts are missing or damaged. Everything should be fine as we inspect each kit prior to shipping.

Notice the numbers or letters marked on the wood. They’ll help you get the correct trim on the correct side.

Start with the front panel, back panel, and RIGHT side of the chest because the left side with the drawer is easier if assembled afterwards. Notice the front and back pieces of the chest have raised slots where the drawer slides into place.

Gently set the dove tails using a mallet and block of wood. You can just use your fist, rapping soundly to avoid breaking hand or dovetails.

Assemble the inner box by sliding the bottom and side into place. You’ll notice the side has notches in the upper corners. Slide the lid into place. You can pre-glue the knob into the hole of the lid, or do that after assembly.

Set the dove tails on the left side of the chest.

Attach the trim pieces with #8 x 1¼" (#8 x 1" small chest) screws. Again, match the like-symbols on the trim with the sides.

Turn the box upside down and attach bottom pieces with #6 x 1" screws. Note how the laps are cut, and that the end pieces have one lap edge, and one square edge.

Once the bottom is set, turn the chest upright. Slip the rope beckets into the becket blocks, and screw on from the inside of the chest using #8 x 1¼" screws.

Now you can set the plugs into the counter-sunk holes on the inside of the trunk if you wish. Dab wood glue on the end. Inserting with a twisting motion will help evenly spread the glue. Tap them in with your block and mallet, then gently chisel off (with the grain) the excess. If you are concerned about gouging the chest, you can always surround the area with some duct or masking tape, but peel it off as soon as you are done with that plug. Some boat carpenters will drill right through their roll of masking tape so as to have sections to peel off and place over bung holes to be filled. Wipe any excess glue with a wet paper towel. Sand or cabinet scrape flush.

Time for the hinges. Install the lid hardware first. Use the short black painted screws for the lid and the longer black painted screws for the hinge on the top edge of the back panel. Even though the lid screws are designed to be short enough to NOT go through the top, be careful. Check your progress using one hand on the lid. You would actually feel the wood move before the screw breaks through.

• 22 #8 x 1" screws for trim (extras included)
• 14 #6 x 1" screws for bottom (extras included)
• 4 #8 x 1 ¼" screw for handles
• 4 short screws for top hinges (for lid, painted black)
• 2 bottom sections
• 26 plugs (extras included)

The WoodenBoat Store, Naskeag Road, 84 Great Cove Drive, Brooklin, Maine 04616

tel: 1.800.273.SHIP (7447) 207.359.4647 fax: 207.359.2058