Make nesting trays for project parts

Plan the nesting relationship

Nesting trays are useful for screws, small wooden parts, and project notes, but their sizes must account for wall thickness and clearance. This set uses three shallow plywood trays. The smaller tray fits inside the next one when empty; loaded trays should be stored separately.

Use measured 6 mm plywood for the walls and bases. Keep the walls 25 mm tall. The outside footprints are 240 × 180, 220 × 160, and 200 × 140 mm. With 6 mm walls, each larger tray has 8 mm more inside width and depth than the next tray’s outside size.

• Bases: 240 × 180, 220 × 160, and 200 × 140 mm.
• Long walls: two per tray, matching the corresponding base length, all 25 mm tall.
• End walls: two per tray, 168, 148, and 128 mm long respectively, all 25 mm tall.

Batch the work without losing identity

Label every base and its four walls as a set. Cut repeated wall heights from consistent stock, then fit lengths to their own bases. A single misplaced wall can make two trays appear almost correct while neither assembles properly.

Check the actual plywood thickness before cutting the end walls. Their length is the base depth minus twice the wall thickness. The nesting clearance also changes with that measurement, so test the complete relationship using the dry-fitted outer walls rather than relying only on nominal dimensions.

Assemble one tray as the reference

Build the largest tray first. Sand the interior faces, dry-fit the corners, and glue the walls onto the base using a suitable adhesive. Keep the wall tops level and the base flat. Once cured, measure its real interior before completing the middle tray.

Repeat with the middle and then the smallest tray. This sequence lets you correct a small dimension error before it propagates through the set. Do not force the trays together; a snug raw-wood fit may become a jammed fit after coating or minor environmental changes.

Organize parts without hiding hazards

Use removable labels to identify the project or assembly stage. Keep sharp screws and pointed parts in an appropriate small container within the tray rather than loose where fingers search blindly. Do not use the trays for hot parts, wet chemicals, or heavy machinery components.

Ease the upper edges and let any finish cure before nesting. Lift each tray from beneath. The thin glued walls are intended for light organization, not as carrying handles or a tested load-bearing system. Empty the trays after a project so unidentified hardware does not accumulate indefinitely.