Turn your Halloween décor up a notch with this simple wooden jack-o-lantern box. Cut a face into the front panel, assemble with pocket-hole joinery, then finish with stain, paint, or a scorched look for spooky vibes. Difficulty: Easy.

Tools & Materials

Cut List

Tip: Confirm your actual board widths (e.g., 1×8 is typically ¾" × 7¼") and adjust the Bottom/Plug length using: Bottom length = Front width − (2 × Side thickness).

Step-by-Step Directions

1. Cut the Face & Back: From the wider board, cut two pieces to your desired height (12" shown).
2. Cut the Sides: From the narrower board, cut two matching side pieces to the same height.
3. Measure for the Bottom/Plug: Stack the Sides on the Face and measure the internal width. Use the formula above to calculate the Bottom and Top-Cap Plug length (about 5¾" with typical 1×8/1×6 stock).
4. Cut Base & Top Cap: From the wider board, cut both to be 1–2" longer than board width to create a pleasing overhang (about +1½" works well).
5. Lay Out the Jack-O-Lantern Face: Draw or trace your design on the Face panel.
6. Drill Starter Holes: Use a ½" bit at interior cutouts; optionally add 1/8" relief holes at inside corners.
7. Jigsaw the Face: Cut out the eyes, nose, and mouth; sand edges smooth.
8. Drill Pocket-Holes: Two along one inside edge of each Side; three around the Bottom (one on each of three edges). Keep holes clear of the face areas.
9. Assemble the Box:
   • Join one Side to the Face with pocket screws (holes facing inward).
   • Attach the Bottom from above into the Side, then into the Face to help keep the box square.
   • Attach the second Side and drive the remaining Bottom pocket screw.
10. Dry-Fit the Top-Cap Plug: It should slide freely; trim/sand for a comfortable fit.
11. Attach the Back: Pre-drill six countersunk pilot holes and fasten with screws (straight-in) so the back can be removed later if needed.
12. Build the Top Cap: Mark centers on the Top Cap and Plug; align, pre-drill, and screw together.
13. Test-Fit the Lid: Slide the Top Cap onto the box; adjust the Plug for a snug but removable fit.
14. Locate & Attach the Base: With the lid fitted, measure the cap overhang offset; transfer that offset to the Base. Mark centers on the Base and Face, align, flip, pre-drill countersunk holes, and screw the Base on.
15. Finish: Sand, then apply stain/paint or carefully scorch with a propane torch for a spooky, textured look. Re-install the lid, drop in a battery light, and enjoy!

Safety & Finishing Tips

• Always wear eye/ear protection and follow tool manufacturer guidelines.
• Use only battery LED candles—no open flames.
• If torching, work outdoors on a non-flammable surface and keep a fire extinguisher nearby.
• For outdoor display, seal all faces and edges with an exterior finish.