As a reminder, this is what I'm working on.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu1ZEag6skNtGkA61DkzJv3MDqVvcRXkUtR9vYIGF8o1ENUET5Ovo2EPxzfPfTIYRTNvZv-xvUWuTRV-srgqIB4ai8vw8CUUs-60zjanDfUBzsMFSKoWFif3hwzjIx75AjqvkWJQOzo24dSESIcstBFiSaUcO8UZpsy0rfCD2lNLTMuHkwCq9H6takFOlp/s320/Repair%20Toolbox%20Front.png) |
The plan |
It's a relief having the design part behind me. I'm not much of a designer and I'd rather be building stuff. Like all of my projects, it started with getting stock to size. I estimate that about 70% of my project time is spent in stock prep. This is all by hand - but I'm starting to see the day coming when I'll have to rely on a bandsaw to help me.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimi1Xo1oxf3MUQIDaZxFQjHrh0bcyAMsVQzG_doNNrONav7JyiBeb1hK5kuepbLLzRRfDW6ep-y0zBxsnPBDb4E07C86YT-7Fn_ZJsGux3BKL7myZp2S3OniQsZDLw9vWiXnmdKEU8f9q806DFpQ_viA2kTGQJ5CsN4PUwEyQzMULzAYIxqCSRpczLOy8X/s320/DSC05821.JPG) |
Resawing a board that will become the front panel |
Once the bottom and ends were dimensioned, I started dovetailing. Tails are on the ends and pins on the bottom to resist coming apart if there is too much weight in the drawer.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8QNuB-rmTMGzSoMfda5kh6J1gb1rkJaZUgoxIRYw3aryFJgSaWTi52UfKhpC2KJJGlorgqVNapYhixlb7t_SOeZIhSrunBcJcrl5AyKaQngJ6rCfT0rrXudCHM2TyDVplxehvT-cDt5KfG1R7d4rE-V2hjC9YaOoKa69rvGqPhwE2LSG8C7QYeJIRXrag/s320/DSC05822.JPG) |
Laying out the tails on the end boards |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPRLNnYhMxlREkbM4jmEAJhbh733bbaqFKW4t0tf3BGnlzFQQfvoKakPGlACx2hsup88CCQCLvz1I6rHuaTKPdmPK9UrUkIHT5myS1vbakkYbjMxSjOXphPXqMo01jQITXinSBbqSq1UCTYuH0u1ku9JzE7tP5lSUoO0ZqnvzqHw9_SYwFEZgQgZENB4T8/s320/DSC05823.JPG) |
Sawing out the waste |
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After cleaning up with a freshly sharpened chisel |
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Marking the pins with pencil before fitting the pieces together |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSNOc3B2yvPGO49E_cBLeqT-1Gyvz9GBDSmPrcYSMcoqGsJvFQ_syyusmlIt6UgCZq18Rwo8klPiLNzIiUQYX_kZVlW1MAxByMU8RAGcZfIGLLWelchicPhI0UminABjsLerdbUZYcIJ9iu1GwWO2j1slIJc1u2sTdvLlxhPpI0yIWpFjt3q7qmQmlGRpU/s320/DSC05829.JPG) |
After a test fit, I can tell this pin is too tight by the smeared pencil marks |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6LTJq9sZ-QOrft2kRELfw2VTz9r50kRLgJBqKk2ep8TMk7tJJEnH6Yx2OsKA-uZBYASp_1izTSAv0mbBfTzoKmR8Pk0ysCx_vMdZlBkp35Cyf7xScY0Ui3iGUbKih4QtIlI5nPblM_NXXd18DxIMZ_M_e9Ywmi0kAuL-rbT9yW8dlmJJUnaZl-zKf-cO_/s320/DSC05825.JPG) |
First corner fitted, after some judicial paring of pins |
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Joint cleaned up (not yet glued) |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioEPEXcmqA0CATPH3k7q2bfoVsWtTNVLgN6dz5KD0vFgn_B17sn8F_QeJNl4ON0vGw7iOZVPkrP-qwAUuCUYv0yb-uY22EC7WsjtiBZfk4UefYOSrizP2agWmGFNXaLGRwgMJ1H84AM_WJ7epUfjc_dM-cEjjcLszbzYijRuHfFPW-RCvDFlIIt4jIhq6D/s320/DSC05832.JPG) |
Here's the setup I used to clean up the tails and pins. I rarely use the slot in my benchtop, but it came in handy here. |
Next on the list was to fit the horizontal divider. I took the shoulder lines from the bottom piece, as their shoulders need to be perfectly aligned.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3UiMkbB5zLOkOX6lGHEKwybSF5MOvsXXBerJU5PV-b7ueRrVTi1-6TUs33ZCIATImEEUlQt881k_Q6aH2fJNan0sSkfUpxrkkDQEYlmHo-eK6Qm4i6lFpJBgaIQvGkT3tpvYddo8UBrMD9x_XBdnHqGdEtusam4q789ArVEJRwfnQULFi-0Os84vrqXRx/s320/DSC05833.JPG) |
The joint marked out |
It might not be evident from the picture, but the sides have five 1/2" x 1/2" mortises marked. The divider has the matching tenons marked. Since my marking gauges won't reach as far as I need for this application, I had to get out my panel gauge for the markings further from the reference edge.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3-JWX_xQNrZonzu5_Iw7YkZo0olE1cpiXYcQAuCgEzva1bmhJUX0JCdXJCl6iiy3CivRGxr84hrSD-JvBA55pNIIhrRfoseAUqrbg-DdZRR5mZV_Ca4tCTKlCVYqQAEMXaz0u3_71pcpj8dwXxAo5bLpn3zFbI-BQ1WInRB45e1DjaAi2g3R0x7yuP8Cb/s320/DSC05834.JPG) |
After boring and paring the mortises and sawing and chiseling the tenons a first test fit shows a nice result. |
I had left the tenons 1/16" long to be flushed with the surface later, but I thought I'd leave them proud on the finished toolbox. Not sure it'll go well with the flushed-up dovetails just below, but if I don't like it, I can always flush them up later.
And here's the box (so far) dry assembled.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_1NuScrJKdkYaGZgJ4RIW6qG1iZgDx7ScChOWeBsigIWqlmlasrp03S11RY7bF76VFslmh1liGM2vv0BqsB7kgjaMs0AQcw64L0ChvhzO5DcK-tbfXB3GKkctGt94O7DlYPC1fAanvtYHtoTfZUJdEY45tdtE0t1ujeNyYgG3vGQTIiNiMdg1SkCPCUVk/s320/DSC05835.JPG) |
Bottom and divider assembled with ends |
Next time I'll write about fitting the front and back panels, doing some shaping and gluing up the box.
That joinery is going to make for a very sturdy box, and it looks great, too.
ReplyDeleteThanks Jeff. Yeah, it's probably overbuilt a bit, but it's solid as a rock. The project is coming along nicely - just have the drawer to do now.
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