File Caddy

I used to keep my files in my tool box, but found that whenever I used them I'd keep making trips back and forth between my toolbox and bench to get a slightly different file. Before I knew it, I had brought almost all of my files over to my workbench.

This happened frequently enough that I decided to would be easier to just keep them all in some sort of caddy I could just bring over and set on my bench, and tuck away on a shelf when I was done.

Materials: Scrap plywood, wood glue, and a few wood screws.

Tools: Table Saw and band saw (a circular saw and jig saw would work just fine), a drill press and set of forstner bits (you could also just use a hand drill), a couple sharp chisels, and a random orbit sander and some sandpaper.

Initially I just threw this wooden tote together out of some bed slats. Even though this makes a pretty convenient tote, this really isn't good for the files. Whenever possible you should try to keep your files from bumping into and rubbing against each other, otherwise you risk prematurely dulling them.

In my case, most of my files were either already pretty well worn or just inexpensive, but the point still stands.

It was time to make a new carrier where each file had its own home.

I started by taking an inventory of my files. Laying them out and making note of how many there were of each type, width, and length.

I decided I wanted to stand the files vertically in a sort of A-frame caddy. I wanted to put round files on one side and flat files on the other side. Each side would have two rows, large files on the inner row, and smaller files on the outer row.

I grabbed a board and drew out my row spacing with a combination square. I drew a perpendicular line every half inch, making a grid. I used this grid to layout the hole placement.

I was going to made the structure out of three layers: the top two would have identical holes drilled in them and the bottom would act as the floor. I cut two pieces of plywood to the same dimensions as my top board.

I used some double-sided tape to hold the top board to one of the pieces of plywood, which would act as the middle layer.

First I set my drill press to only drill halfway through the second board, and drilled the small holes for the short needle files.

Then I set it to drill all the way through and drilled the rest of the holes.

For the slots meant to hold the larger flat files, I started with a series of holes and then connected and flattened them with some chisels, rasps, and files.

I cut the sides to the same width as the horizontal layers, then cut a taper on the bandsaw, and drilled a hole for the eventual handle.

I didn't go overboard with the sanding, since this was a piece of shop equipment made from rough construction plywood.

I sanded the faces with 80 grit on my random orbit sander, and softened the edges and corners with a piece of 100 grit sandpaper.

I cut one more piece, a 4" strip to give some lateral support and act as a spacer between the bottom two layers. I attached them to one of the sides with wood glue and screws.

I used a block as a spacer to add the top layer and then the other side.

For the handle I used this one inch dowel. It ended up being a bit oversized and I had to convince it into place with a mallet, so I didn't feel the need to glue or pin it.

Since the needle files stopped at the second layer, I made this little box under them to hold some sanding sticks and this oddly shaped contour rasp.

Lastly I added a little hook to hang my file brush and stenciled my initials on the side.

Now all that needed to be done was populate it with files!
I made sure it would hold way more files than I currently have so there was plenty of room for future expansion.

This is something I've been meaning to get around to for a while, and it feels good to cross it off the list. I'm sure my files appreciate it.

It was also nice to open the garage door again and make some sawdust after a cold winter. The whole thing took about three hours working at a leisurely pace.

This project was completed on February 27th, 2021. View it on Instagram.