Hollow Out a 2×4 for Your Next Project Enclosure

Photography by Ben Light

If you’re anything like me, then you have a lot of scrap wood lying around the shop and a bunch of electronic components on the workbench. Why not put them together? The following steps will show you how to create affordable, custom project enclosures out of common, inexpensive 2×4’s.

You will be primarily using the bandsaw, the drill press, and a few specialty drill bits. This technique produces interesting looking devices that have a very handmade feel. Perfect woodworking skills are not required, in fact, a little roughness gives the object more character.

I really like how the enclosures turned out, the analog components and the 2×4 look great together. Whenever someone comes into my office, they almost always pick one of them up and fiddle with the knobs and switches.

I will definitely be making more of these. Next time I might route out the enclosure instead of using the drill press. Or even CNC the inside so components can fit with precision.

Before you start construction on the enclosure, it’s a good idea to have a completed electronics project that is ready to be enclosed. This way you know what will be going into it and how long to make it.

Never use power tools if you are not sure how they operate, and always wear the proper protective gear.

Let’s get started.

18 Responses to Hollow Out a 2×4 for Your Next Project Enclosure

Scott Tuttle on September 18th, 2015 at 8:10 am said:

reminds me of a bandsaw box, which would be easier to make I’d think.
Andy III on September 18th, 2015 at 1:13 pm said:

Coooool! Love it.
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allangee on September 22nd, 2015 at 11:02 am said:

If you pre-thread the holes with the screws before the cut, it won’t account for the kerf — unless the holes on the cover plate don’t have any threads on them.
- michaelseanhansen on September 22nd, 2015 at 11:20 am said:
  
  I think you drill the holes first for the sake of alignment, then cut the plate, then thread the holes after.
- alrui on September 22nd, 2015 at 10:17 pm said:
  
  Youre using wood screws so there are no “threads” in the common sense. Just run the screws in when youre all done and you’ll be just fine:-)
alrui on September 22nd, 2015 at 10:16 pm said:

Those make much nicer enclosures and are far more environmentally friendly then a cheap plastic box!
pcf11x on September 23rd, 2015 at 9:25 am said:

I have drilled out blocks of wood like this in the past to make boxes with and sometimes the wood warps really badly. I am not sure why it happens, I just know it has happened to me. Mostly it works just fine though. So it is obviously something to do with particular pieces of wood. Maybe some wood I’ve used is just too wet, and the heat of drilling it warped it, or the wood was under a lot of internal tension? I don’t know.

All I’m saying is I have seen this go horribly wrong. Although when it works it is nice. Nice enough that I have done it a number of times. Enough times to have seen it fail miserably on occasion. Hogging the middle of wood out is just pretty intense on a little piece of wood.

When I’ve done this I’ve done it on my milling machine so that might have been a factor? It has more power than most drill presses. I do tend to use it that way too. It does seem to occur more the faster I drill the wood out. Like the wood just can’t handle the rapid change?
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splud on March 2nd, 2016 at 12:27 pm said:

I’m prone to cutting the front and back from the “box”, and then hogging out the centre (which can be done easily with a single drill hole through a corner, then use a jigsaw, scrollsaw, or coping saw (non power tool) to remove the entire centre mass. Glue the front back on and run the rest of the project just as you present in your article.

Starting with a clean bandsaw blade will result in less burn on the wood.
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Mike on May 13th, 2018 at 6:26 am said:

What are some ideas to utilize this enclosure?? Many thanks
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Cep Model on December 30th, 2019 at 4:29 am said:

Those make much nicer enclosures and are far more environmentally friendly then a cheap plastic box!
dijitalportal on January 4th, 2020 at 9:57 am said:

It seems to be an easy project. thanks for sharing. will try soon…
weilbet on January 25th, 2020 at 1:16 am said:

thank you so much as asssd reminds me of a bandsaw box, https://weilbet.co/bedava-bonus