Building a casket may not be something most people consider, but for many, it’s a meaningful way to honor a loved one. Just like crafting a dining table or a cherished rocking chair, constructing a casket allows you to create something personal and significant.

You don’t need to be an expert woodworker to take on this project. With basic tools, patience, and attention to detail, you can build a casket that not only saves money but also carries deep sentimental value.

This guide will take you through the entire process, from selecting the right materials to adding personal finishing touches. Whether you’re making it for yourself or a loved one, this project is a heartfelt and unique way to say goodbye.

Understanding the Basics

A standard casket is typically 84 inches long, 28 inches wide, and 23 inches high. These dimensions can be adjusted as needed, but it’s essential to check local cemetery regulations, as some have specific size requirements.

For tools, you’ll need a circular saw, drill, measuring tape, and screwdrivers. A router is optional but helpful. The entire process usually takes about 20-25 hours, spread over a few days to allow for glue drying and finishing.

Safety is crucial. Always wear protective eyewear, a dust mask, and work in a well-ventilated space—especially when working with hardwoods, as the dust can be harmful.

Before cutting any wood, ensure you have a dedicated workspace of about 50-60 square feet. A sturdy workbench or sawhorses capable of holding at least 100 pounds will make the process easier.

By thinking of this project as building a large wooden box with specific details, the task becomes much more manageable.

Choosing the Right Materials

Pine is the most practical wood choice—it’s affordable, easy to work with, and biodegradable. You’ll need approximately 60-70 board feet of 1-inch thick lumber. Cedar and oak are also great options but tend to be more expensive. Avoid pressure-treated wood, as it contains chemicals that are not environmentally friendly.

Materials List:

• 6-8 sturdy handles (stainless steel is ideal for durability)

• 2-3 lid hinges

• A simple locking mechanism

• Around 100 wood screws (1.5 to 2 inches long)

• Cotton or linen fabric for interior lining (5-6 yards)

• Polyester batting or natural wool for padding

A pine casket generally costs between $400 and $600, while premium hardwood options can range from $800 to $1,200. This is still a significant savings compared to commercial caskets, which often start at $2,000.

It’s always a good idea to purchase about 20% more material than needed to avoid running short mid-project.

Preparing for Construction

Start by clearing and leveling your workspace. A garage or covered area with good lighting and protection from moisture works best. Set up sawhorses about four feet apart and lay down a drop cloth for easy cleanup.

Allow the wood to acclimate to your workspace for 48-72 hours before cutting to prevent warping. While waiting, create a full-size paper template on the floor using builder’s paper or cardboard. This helps visualize the dimensions and catch measurement errors early.

Cutting List:

• Two 84” x 28” panels (top and bottom)

• Four 23” x 84” panels (sides and ends)

• Support braces every 16 inches

• Lid trim pieces

Mark all your pieces clearly before cutting. Use a carpenter’s square for accuracy—small errors can add up over the course of the build. Labeling each piece according to its location and wood grain direction will help achieve a well-matched final look.

Before beginning assembly, organize your tools and materials so everything is within reach. This will make the process more efficient.

Building the Casket

The base forms the foundation of the casket. Cut the bottom panel and attach 1x2-inch support strips every 16 inches across the width to prevent sagging. Secure them with wood glue and 1.5-inch screws, drilling pilot holes first to prevent splitting.

Attach the long side panels first, overlapping the shorter end panels to create stronger joints. Apply wood glue at the seams, then secure everything with screws every eight inches. Wipe away any excess glue immediately to ensure a clean finish later.

If you want a viewing panel, the lid will be built in two sections. Reinforce the main lid with a frame made from 1x2-inch strips and cross supports before attaching the top panel. Lightly sand the edges for a softer, finished look.

Install three heavy-duty brass hinges—one near each end and one in the middle—ensuring they are perfectly aligned so the lid closes smoothly.

For added stability, install corner braces inside (4x4-inch triangular pieces).

Handles should be positioned 16 inches from each end and centered vertically. Use bolts instead of screws for greater strength, and reinforce the interior with backing plates.

Test the lid to ensure a 1/16-inch gap around all edges for smooth opening and closing. Adjust the hinge positions if necessary.

Interior Work

Begin by adding a layer of 1/2-inch foam padding to the bottom and sides. Use spray adhesive to keep it in place. For extra comfort, apply two layers of batting over the foam, securing it with staples every four inches along the edges.

Cotton broadcloth or silk makes for an elegant interior. Measure carefully—you’ll need about three yards for the sides and bottom, plus extra for the lid. Use upholstery pins to adjust placement before stapling the fabric in place. Neatly folding the corners will give a polished appearance.

Make a pillow that is slightly firmer than usual, around four inches thick when compressed. Fill it with polyester fiberfill or wool, and consider adding a zipper to allow for adjustments.

Tuck in all raw fabric edges and cover staples with decorative trim to achieve a professional finish.

Finishing Touches

Smooth all surfaces by sanding with 120, 180, and finally 220 grit sandpaper. Pay extra attention to edges and corners.

For finishing, tung oil is a great choice, as it enhances the natural wood grain while offering protection. Apply three to four thin coats, allowing 24 hours of drying time between each layer. Unlike polyurethane, tung oil preserves the wood’s breathability and is environmentally friendly.

Polish metal hardware with a soft cloth, and apply a light coat of wax to brass components to prevent tarnishing. Check all moving parts—hinges should operate smoothly, and handles should feel secure.

Consider adding personal touches, such as wood-burned inscriptions, family crests, or meaningful quotes. Some choose to create small hidden compartments for letters or keepsakes.

Pressed flowers or leaves sealed under a clear tung oil finish can add a natural decorative element. For veterans, service insignias can be inlaid into the wood. Inside, quilt squares or embroidered messages in the lining provide an additional heartfelt touch.

Final Thoughts

Building a casket is a deeply personal and meaningful endeavor. While it requires time and effort, the result is a handcrafted tribute filled with love and care. For those who prefer a professionally made casket with personalized details, Discount Caskets offers high-quality, customizable options that meet all funeral home requirements, providing peace of mind during a difficult time.