How to Build Retail Display Fly Boxes

Fly fisherman of all ages love to go to fly fishing shops. The rods and reels, waders, and a host of specific tools grab everyone's attention. But what is perhaps the most awe-inspiring aspect of these shopping trips is perusing the thousands of flies on display. From tiny insect imitations to large flies meant to look like fish, looking at these examples of fishing art are exciting as we imagine the fish-catching potential of each and every one. What makes it so easy to shop for and locate the particular fly we want is the box in which it is displayed. These wooden boxes--intricately crafted and functional--help organize the flies by style and size. While they are needed from a purely functional standpoint, they often become the center of activity in any fly shop.

Things You'll Need

  • 3/8" birch plywood
  • Circular saw
  • Drill
  • 1/16" drill bit
  • Hammer
  • Finish nails
  • Wood glue
  • Sandpaper
  • Wood stain
  • 1/4" birch plywood
  • 1/8" basswood
  • Utility knife
  • Drawer handle
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Instructions

  1. Build The Drawer Enclosure

    • 1

      Cut two pieces of 3/8" birch plywood for the top and bottom of the fly box. The dimensions should be 25" wide and 18 3/4" deep. Our box will have the inside clear dimensions of 24" by 18", so we have to allow for the thickness of the plywood and the drawer slides in our dimensions for the top and bottom pieces. Cut two more pieces for the sides, with dimensions of 18 3/4" by 9 1/2". This will allow us to have three 3" tall drawers, plus room between them for smooth operation. Cut one piece for the back with dimensions of 25" by 10 1/4". This dimension is the 9 1/2" clear plus the 3/8" for the top and 3/8" for the bottom.

    • 2

      Attach the drawer slides to the inside face of the side panels. We will have three drawers, so each side piece will have three slides. Be sure to install with the rail facing up, using the small screws provided with the slides. The rails must be level, so use a straight edge or ruler to mark three parallel lines where the slides will be installed.

    • 3

      Drill small 1/16" pilot holes along the top and bottom edges of the back panel. These holes should be about 4" apart along the length of the piece. Drill similar holes along the left and right edges of the top and bottom pieces. Attach the top, bottom, back and side pieces together, using small finish nails and wood glue.

    • 4

      Allow the glue to dry completely, preferably overnight. Use a nail set to set the nail heads below the wood surface, fill the holes with wood putty, allow the putty to dry, and sand to a smooth finish with fine-grit sandpaper.

    • 5

      Stain the box with your preferred stain color. If two coats are required, lightly sand the box between coats for a better finish.

    Build The Drawers

    • 6

      Cut three pieces of 1/4" birch plywood that are 17 5/8" deep by 23 1/4" wide. We need the drawers to be smaller in all dimensions than the box we are putting them in so that we have room for the drawer slides. Cut two pieces of 1/4" birch plywood that are 17 1/4" deep and 2 3/4" tall for the sides of the drawers. Cut one piece 23 1/4" long and 2 3/4" tall for the back. One more piece, 23 1/3" long and 3" tall, will be the front. This piece will overlap the bottom piece so that the front of the drawer is a solid piece with no joints. That is why it is the full 3" height.

    • 7

      Build the drawers using a similar process that was used for the enclosure. Drill small pilot holes along the edges, use wood glue and finish nails to attach the pieces, set the nail heads, fill with putty and sand smooth.

    • 8

      Cut 1/8" by 3" basswood into 23" lengths using a utility knife. Basswood is relatively soft and easy to cut so this hand tool is the right one for the job. Since the inside clear drawer height is only 2 3/4" high, you need to cut off 1/4" from the edge of the 3" basswood. Also, notch the top of these pieces 1/2". These notches should be located at approximately 2" intervals, but larger flies will require bigger dimensions. These pieces will form the section dividers for the fly storage and display compartments. For the dividers that run left to right, you want to set them at approximately 2" intervals. Mark the base of the draw every 2" starting at the front of each drawer and work your way to the back. Glue these pieces in place with wood glue and allow the glue to dry.

    • 9

      Cut more 1/8" basswood strips, this time for the dividers that run from the front to the back of each drawer. The dimensions on these will be 2 3/4" tall and 17 1/4" deep. Mark these pieces every 2" starting from the front and work your way back. Next, cut 1/8" wide and 2 1/4" tall notches into these pieces so that they can fit down over the dividers already in place. Rather than gluing these in place, simply slide them down over the other dividers at the locations of the other notches. Drill small holes in the front of the drawer and install drawer handles that help open the drawers. With all pieces in place, stain the pieces in a similar fashion as you stained the box, allow the stain to dry, and slide the drawers into the drawer enclosure. Other than filling the compartments with flies, the task is complete.