There’s just something about an old wooden toolbox that is kinda cool. I’m not sure if its the rugged sturdiness, or the simple design, but before there were 5 gallon bucket tool sleeves, I’m sure everyone had to have one.
Brianne was given one a while back that now sits in our entry way to hold random stuff that we grab when we leave, and drop off when we come home. She mentioned making D a toolbox like that to help organize some of his tools and toys. Seemed like something that we could put together in an afternoon and we had some pine boards from Home Depot when they were selling them for for less than $2 each a few weeks back.
Here’s the sketchup for the toolbox we built.
I started by cutting one of the boards to 18″ long, and then ripping it to 6″ wide on the table saw.
We repeated the same process for each side, cut to 18″ long, and ripped them to 3 3/4″ wide (could alternatively use a 1×4 cut to size).
Once you have those 3 pieces cut to size, its time to work on the ends.
We started by cutting a couple of new pieces to 6″ x 8″ and then marked the top of the side with 2 marks, each 2″ in on either side, and connect them with a line. This was done using the speed square.
Once we had both ends marked, we used the table saw to cut along the lines.
Next, its time to drill the holes for the handle. We chose a 1″ dowel rod, so we used a 1″ spade bit to make our hole. We drilled our hole about 2″ from the top. When drilling your hole, you only want to go about halfway through. We then drilled our pocket holes to attach the end to the bottom and sides.
Then some more pocket holes on the bottom piece. We put 6 on each of the long sides.
The last piece we cut was the dowel for the handle. This took a little trial and error, but assuming you drilled halfway through on either end, a good starting point would be 17 1/4″ (18″ for the length of toolbox – 3/4″ for the holes). After the initial cut, dry fit everything and make sure the handle fits. If not, trim a little at a time until you’re happy with it.
Everything is cut, and we’re happy with the dry fit…on to assembly.
We attached each side to the bottom with our pocket hole screws. We used clamps to hold the bottom and sides together, along with inserting the end to help hold up the sides.
Sometimes its good to have an extra set of eyes on thing to make sure you’re getting it right.
Once the side are on, you can then turn your attention to the ends. We ran into a tight spot while attaching the ends that required a trip for a new tool, but if I had to do it over again, I’d definitely move the pocket holes to the outside, rather than the inside. (Another alternative would be to use a nail gun) After the first side is attached, insert the handle as you slide the last end in place, and screw in the last of your screws.
That’s it…now you have a new toolbox.