In this video, I had a local client who wanted a custom whiskey box built for a wedding toast.  Six friends from college started a tradition that as each one got married, they would commission a commemorative box to be made to house six shot glasses and the groom’s favorite whiskey.  They would then have a toast to that groom’s loss of bachelor’s life freedom and gain of a family.  I was honored to have built the box for groom number 5.  The box was so popular that I have been commissioned several more times to build similar boxes for similar occasions.  If you want to build your own whiskey box, I have plans available.

Building a Custom Whiskey Box with Six Shot Glasses – A Detailed Woodworking Guide

If you’ve been following my YouTube channel, you may have seen this whiskey box build before. But when a client commissioned another one, I decided to document the process in even greater detail. Below, I’ll walk through each step of crafting this elegant whiskey box, with six embedded shot glasses and a bottle holder.

Plans are available for download if you want to make one yourself!

Choosing and Preparing the Wood

Selecting the Right Boards

I wanted the grain to flow seamlessly around the box for a cohesive look. Normally, I’d cut the lid and sides from the same wide board, but my lumber yard was low on stock that day. Instead, I found a separate piece with a similar grain to maintain visual continuity.  The top of the box is made from Genuine Mahogany, while the sides are made from walnut.

Milling and Marking

After milling the stock to thickness, I marked the sequence: side, front, side, back, ensuring the grain would wrap around the box when assembled. This subtle detail elevates the final product.

I used a stop block at the table saw to cut the base and top pieces simultaneously, guaranteeing identical lengths.

Cutting and Fitting the Box Joints

Setting Up the Jig

I chose box joints for strong, attractive joints. I set up my miter gauge with a spacer (matching the joint width) to ensure precise spacing. A test cut confirmed the fit—too loose looks sloppy, and too tight risks breaking the fingers.

Scoring to Prevent Tear-Out

Before cutting the joints, I used a marking gauge to score the exit side, minimizing tear-out. This mark would later be sanded away.

Cutting Thin Pieces Safely

The thin lid pieces felt unstable, so I clamped them to a scrap plywood backer for support. I also made plywood clamping cauls with matching finger patterns to apply even pressure during glue-up.

Assembling the Box

Fine-Tuning the Fit

Since minor setup errors compound across multiple joints, I left the sides slightly wide when ripping them. After assembly, I trimmed them to exact width for a perfect fit.

Using Epoxy for a Swell-Free Glue-Up

Standard wood glue can swell the joints, making assembly difficult. Instead, I used epoxy, which acts as a lubricant when fresh and ensures a tight, gap-free fit.

Squaring Up the Case

After the glue-up, I hand-planed any uneven edges. Then, I installed hinges by knife-marking their locations, chiseling the mortises, and finishing with a router plane for clean recesses.

Building the Interior: Shot Glass & Bottle Holders

Designing the Shot Glass Layout

I wanted a staggered, clustered arrangement near the bottle end. I measured the glasses using calipers and selected a matching Forstner bit to drill the recesses. A ¼” round-over bit softened the edges for a refined look.

Adding a Protective Spacer

To prevent the glasses from being pushed too far down, I milled a spacer block covered in felt, which gives the glasses a soft landing.

Crafting the Whiskey Bottle Holder

I turned a mahogany piece on the lathe to fit the bottle’s neck, then notched it on a spindle sander. After positioning it in the box, I secured it with screws and epoxy (which fills gaps caused by the felt lining).

Lining the Box with Felt

A Lesson in Spray Adhesive

I typically use 3M spray adhesive, but the store was out, so I tried Gorilla Glue’s heavy-duty version—big mistake. The edges peeled up, forcing me to scrape it off and redo it with a better adhesive.

(Pro Tip: Always test adhesives on scrap material first!)

Installing the Felt

After taping off the edges to avoid overspray, I:

1. Pressed the felt into place with a plastic putty knife.
2. Trimmed excess with a razor blade.
3. Epoxied the glass holders in place for a secure fit.

Final Touches

• Brass clasps were added to keep the box securely closed.
• Sanded and finished the wood with a smooth, protective coat.
• Loaded it up with a whiskey bottle and six shot glasses—ready for gifting!

Why This Makes a Great Gift

• Customizable: Choose different woods, finishes, or engravings.
• Functional: Keeps glasses organized and displays a favorite bottle.
• Handcrafted Appeal: Far more meaningful than store-bought alternatives.

Final Thoughts

This project blends precision joinery with practical design, making it perfect for whiskey enthusiasts or woodworkers looking to hone their skills.

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