Last post I had completed the main box. This time it's on to the upper tray and drawer. For the tray, I made the depth (front to back) a little more than 1/16" less than the inside dimension of the box. It's length is about 3" shorter than the inside length of the box. This was to allow a drill to stand up on the floor of the upper compartment and still be able to put the tray in place.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjktC-fG1plp2tXca2JBDdNI5SUu_G48GNDi0V2So8pAQzwdmFbjAoxgiq60ckNGMDEWQf-uYP9Q66iZqnscvwqnlNFt0JYG6bVkTXQENYzzTyC_G8emvvIvoq54WxucB8bDWmo_5h2Ba4Wynk1DdstMptZb7c9JS7Wt69yVY7UzKrOMg-O7cfVdBHp8GC5/s320/DSC05844.JPG) |
The 3/8" thick tray components dovetailed |
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... and test fitted into the box |
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Made a handle / divider that fits into stopped dadoes in the ends. The handle is 1/2" thick to add a little comfort when picking it up. |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9q1FKYSfYZBPBBewi_LcXQ8KXIs0iLAuGMS8NejXCV6rWaLbWZJeAsvQEO8bLBeCEUiFrdkwA0-ARSsNmsroWsjngQ725Re5HerLd8AbJBZ9b6V4Kw_WvwUzSLePSpjYvZfu4SQyqPv3jvMH9plBW_TqCDwuFVgPtUxswfS6H1QsJFptHy14Zp9WRSVmM/s320/DSC05850.JPG) |
Close-up of one end of the handle / divider |
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One corner of the tray with cleaned up dovetails |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtaWHn2Jzz2xZazSjGguA8o7wru6DUr7Wou4MP9FB_dTv6TVBAgpyZpldHeuNZ82W1Y27Tw3W95Ua3G1KcNFGAPZgPiW_bScltlhM4ILHXtgZ3mlpjbjXaVe7zyuRkEo4rrgo6j9hwkOUu1bAvkATYrROWTYCqfqeWV6zQ5YbJIVkw82bFjNznp6bDN69U/s320/DSC05847.JPG) |
Glued up the dovetails first, then later glued on a 1/8" plywood bottom with some creative "clamping" |
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It fits! |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-zyYX3Wbv8rMKejfVEiTMf1rRYIhUn4hBPPCC6xcXsiapahaVl6aaDvALkQOZoWhAg0QgTYWXHJk1JCBAj4g9XnrSdBWMa22qDVKGm86PEwCH4jUqgSwQtR6f_7dhSaSLhbQHBvHdz2tsWohbGrcrAlj5CU3ZW4Gebc08FBXYhCzpnCLWzqKRFcX4lPhr/s320/DSC05853.JPG) |
I made the height so it would stick up 1/8" from the box upper edges |
I just love fitting drawers to openings. After the drawer front and back were fitted to the opening and the drawer sides to the depth, the drawer was dovetailed together.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjG3tVs2xkNY2ONEJIrxPuqd_8l4sbAf_A4wxKJ3iHNZDH84XpEY5GO_dTMdIHCrzKfmqfOpvvlXrbZqQXPUijl1c7XVOdLCq4MzDGkV_A6uqnypEFG2YX2nBFvAsd0WWCYqXYJTvRnyHLTLBZy_OxcoBOJVJMGjHW65_rzxsXZWMUXinXcez6ulYR1NLty/s320/DSC05856.JPG) |
Fitting the front into its opening |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqtlOdRT9406YmN1CdBbkFyz_kcyxKrKuRqcvCM8JJdKr06iUmOhsKbJ1H3_0M4lJdLhJtL5O9v0oc6IE84EQ5MoErTwzXMa_RwJRmxSzIOsyTvKtgpxma8n5HLDLlR83hIOrv7dk_tTrUDS6WOWI5Su1SFi9C_ulGhzxQe02-IrGQ3A4g98xHsCoP1xOo/s320/DSC05861.JPG) |
Fitting the left side and getting its length directly from the box |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhF_jrT843D3CxVPzrmrOzFqPDVRZlfYizPxRpAt2LTbUg0jlJAvky1mZsC5IG-goj4dmzqdRBQDKevtkdAgezMpLzjinJ7buvQsgCMenh8Vn1gMQu4bGMMWzHDWPIuVog8KdLYtJwxqQ9pq5Ce39tv-ZioelMyu6ixFSvJzv-np7CkWjMEajVAy2LE5E0-/s320/DSC05858.JPG) |
The parts in relative position |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiF5nAfKtbvg5AZDtUBkKwnjZLg_W46aMRnfqSBlyDdd6wosdHcr13rhSFuXju8C73uEldetu6q8j6LZ1yHOF0o0CxMHFcqRsqn7n4kRfUQW0XLwxpowA8ss8TlpKJpbNule5B7N1mnR0H2ckwJ6A47dUJ9yY1XnDFPiU7wzeLMfsZ1kT2Pl2LNzzgyJYK/s320/DSC05859.JPG) |
Marking the sides with a triangle |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKArEyf2LxFVWVgooBy4Y90abPHDq5ursnsgo2AxpxElOaK-Qn2sJ1G-DrFPAITpZnMVche2YJEAU0u04CDoey9QghWNklNaRlOC4AzM_U0VbA6RZinBJy4ck-tJSDeJCr9E7BGXjQLDN7sQ1aXPIGHWueVOuY0V8fo0UwRmjEfotbs_zlZngqVu_w5MUd/s320/DSC05860.JPG) |
... and the front/back with a triangle. I sometimes use a double triangle so I don't confuse it with a reference edge mark |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_N2NVYGfaJxzKO7PXJ5R5aq0pGURNBGsaiYyJMvlYJTgZp9RhZgyjp8ZYQLXTA2UJbp3KgeUNdiwmLRNqcfZwlYU3MaMz3uFSyz7SW9jCVkTzG4ONpLD43UTrjcF3qJMYvRsRvbHF-2Qiw1YGDcdqDNLlFgYtTRqFLi_c4RJXrUSLuvrPPud7UAVKQMkj/s320/DSC05863.JPG) |
Dovetails complete |
I had another decision to make. Do I plow grooves for the 1/8" plywood drawer bottom, or do I glue the bottom to the underside of the drawer? I did a little test groove in some scrap to help with this.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzyXY5hE19nrdbtckguso2Vnlaz1jTLcwhyphenhyphenSMH01nbw2LPeTzch3aiI5q_ZrF4N6rcGY-eLDr5opl8TFiAfsrOANNqvC9r8ye0dvEYARpyv6ylTJ3OIbVSs6R4R4I8IIMkCI9wLhEhh0WBNKEa4SeDAk5wpF-rXRKilwTgsdRLBvC7KfokIcBv5khbcndB/s320/DSC05862.JPG) |
1/8" groove with some scrap plywood fit in place |
First, my 1/8" plow iron is a bit wider than 1/8", and the plywood is a little less than 1/8", so the fit was sloppy. Second, if I inset the groove 3/16" or 1/4" from the bottom edges, I would lose 5/16" or 3/8" of useable space in the drawer. So I decided to glue the plywood to the bottom of the drawer. But since I sized the drawer components precisely, I had to remove the thickness of the plywood from the drawer parts. On the drawer front I used a rabbet so that the plywood would not be seen with the drawer closed.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjc3Rfp-hm_xyZN6NtKuRUTdhepKIWAj5AIuN0xuAfUzZMg9LLnvcR1XHJSNUJhI89NswMH6gW1n4D7WUwTo_L2mrbQN11ZTpk8c3NXlEUeZyzTn3uOCDpar34WsS30ZYZcxEokuESIBzrW89C-x0O6R_4fhbp1npCbVNUOsRnX98QBUiYS8mfBtjY5wdsv/s320/DSC05864.JPG) |
Here, I've glued the dovetails together and also glued the bottom to the drawer, using the metal toolbox as a clamp again |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjk7ivfMurxg88K86I5WgfgRU72X0BNhT1e9KgkYMuCZjOkfxrAE4qJnLz45pNCL7mVpP9WK9i45Ra2g96hRhaM4ZqhB-cP4ATdPdY7RMixmQxE3pe5R_0Mm_jhGDO0_HFmOZG-sVMzGEwB3ytGnM3bWpVT2WfnB95qZ6FptBVPSMkPSFaEp3DqX6ke8g1r/s320/DSC05865.JPG) |
Then I cut out a bit of the front to form a finger pull |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbHtZokW81DUYkvnjsmqoFmq33nR7lFJVzAFDneVS4FsJ0kZcW4Afxpa3_M1imbsobRe4KwMbBhUBtmUlklaF1BgUe4qtRt-qEBtieNyDD11UbCWnAaqdqniCO6exvWYnzCUAQ6imfANfH4u1fsP2-JnpeXe29SvmAZSn26fyhjZRZBJ44zt3WyUjEJwVc/s320/DSC05866.JPG) |
And lastly I could do the final fitting all the way inserted (before the finger pull I had no way of pulling the drawer back out!) |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu4hZ9zVBijeb3KXtPDo0w_X8C0iEtVlWGTOzONOSWajxfr7o0G4QJARDJQHaKRgFrD6TNPhcN1Ry9GN2fE8tntYMAYNFnxGZpMK8bejF1v8IeaFM-NWBHnGtl6PVd5VjfN2lBISr4x-GDjmfYidbl20xCumkolRXTuqN9Zg1-GsGow8nhX41xR_BjdFqm/s320/DSC05867.JPG) |
Added a couple coats of shellac |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5SCI43agnaD6ghcotUCevPg_Nk4SQQZ5iofyNFXmRvbkH9NKmCsfarlMiXkHpQtnVU0utxUkUcMBnofSXdEBJ83zsUHHbZ7TCoEfCkmZDY-iFmC6oW4XvdT5zd2mGYIo1E4kbT83kr14d1U3GTDUl2IpyzDZRG3XennNPWqzBBO-x6wIMPACrbgpreNR7/s320/DSC05869.JPG) |
And here it is partially loaded, ready for work |
This was a really fun build. It's solid as a rock, but a bit heavier than I might have liked. But that's OK. It's built for a purpose and I think it'll serve that purpose well.
It turned out great, I'll want to remember this one. And the double triangles.
ReplyDeleteThanks, Jeff. I really enjoyed this project. And it should come in handy.
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