It is the penultimate tool box because, in my opinion, there is no such thing as the ultimate perfect tool box. What could come close is the entire workshop with all the tools in it, if you can carry the whole thing with you. And that is the key to a tool box. Portability. With that criteria, the best we can hope for is to get close to the ideal. This is version 4 for me. What prompted it was the last project on installing the two drawers to an existing desk in the house. I made so many trips back and forth, for this and that tool. There is just simply no way to anticipate everything one needs inside the house without a few trips back and forth. So, here I go again.
This is a specialty tool box in that it is designed for specific tools but the methods used can be adapted to your particular tools.
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| I cut these panels first. They will determine the inside dimension of the box |
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| A dado blade set makes quick work of creating the dadoes as shown in next photo |
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| Cut parts complete with 45 deg miters at each end, dado and 1/4 inch channels for the "floor" panels in each box |
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| Glue up assembly |
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| Scroll saw, or alternatively coping saw, was used to cut profiles of the drill battery base outline and reinforced with plywood backing (glued) |
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| A dado blade set cut a channel on a piece of walnut, then ripped in half to create angular pieces to reinforce the corners.. |
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| The corner of a miter joint is not the strongest. So, an angular reinforcement at each corner is very effective. |
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| Glue and screws later make these corners very strong. |
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| Drilling various hole sizes for different drill accessories |
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| The handles were 3 layers of laminated 1/4 plywood (glued) |
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| Drilled 1-1/4 inch holes on two layers of laminated plywood, then glued to another layer, it makes sense with the next two photos |
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| Dry fitting |
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| Dry fitting with the drills in place |
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| Lines drawn before tapering at the table saw |
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| Drilling 1/4 inch holes for drill bits and other accessories |
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| Finishing with wipe on polyurethane |
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| This hardwood bar - glued with screws - is a key "anchor" component where the uprights of the handle will slide into. A bolt knob will hold it in place while also adding more anchor strength (see next photo). |
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| The upright of the handles will be secured two ways: The notch on the upright will slide into a bar, then a 1/4 inch bolt and knob will keep it in place |
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| The thin hardwood pieces are where the plastic bins will clip into |
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| Between the bolt and the slide, there is plenty of holding power to carry the heavy tool box. |
Obviously, this is customized to my set of tools but the idea is to create a tool box for your needs.
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| The screws that secures the 1-1/4 rod is not completely tight to allow for the handle to rotate ever so slightly. This prevents the stress on the hand grip when carrying the tool box |
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| View of one side, showing some of the "quick-connect-disconnect" drill accessories |
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| View from the other side |
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| There will be less than a dozen times in a year that this tool box will venture out of the workshop, so it will mostly be on a shelf. It was worth all the trouble because it does get the tools organized. And when the need arises ... |
