Nail and Tool Box

I made a wooden tool box only using a 24" x 24" piece of 1/2" plywood.

Cut list:

1 - 9" x 15" (Bottom)

2 - 9" x 6" (Ends)

2 - 4" x 16" (Sides)

2 - 2 1/2" x 16" (Inner Dividers)

Handel Material:

1 - 3/4" x 3/4" x 15" Round hardwood dowel (Handel)

1/2" 24" x 24" sanded plywood

Circular Saw

Tape Measure

Pencil

Square

Kregg Accu-Cut (Not Required)

Miter Saw

Bar Clamps

Drill

Countersink

2" Wood screw (2)

Finish Nails

Wood Glue

Wood Filler

Sandpaper

Paint/Stain of your choice

When planning your cuts, it is important to layout all the pieces that you are going to need to reduce waste or cutting yourself short. For this project, the 4" side pieces must be cut first or you will not have enough material. For the inner dividers, use the (2) 2 1/2" x 16" to cut down to best fit your needs. I cut one to 15" to stretch from sided to side and (2) at 4 1/2" for dividers. For the ends, I used some double-sided tape and taped them together before I cut the angles (See Picture) to make sure I ended up with mirror copies of each. One side note, make sure to make accurate cuts and verify the thickness of your plywood and make any needed adjustments.

For assembly, I first laid out all my pieces in how they were going to be assembled. Using glue and 1 1/4" brad nails in my gun I attached the two ends to the bottom. I then glued and nailed the two sides to the bottom and the ends. Using bar clamps in this process can help but not required. Next I assembled my two divider pieces to my long 15" piece. I then aligned the dividers on the bottom side of the box and traced a line around them so I would know where to fasten nails. I then glued the bottom edge of the dividers and but them in place. Holding the dividers in place, I flipped the box over and placed nails in between the lines that I had traced. Lastly is the handle. From the top edge of the tool box, measure down and mark a spot 5/8" down on the center line. I then used a counter sink to drill a starter hole. In the 3/4" dowel rod, mark the center point of each end and drill a starter hole for the screw. Using your two screws, fasten each end of the handle to the ends of your tool box.

How you finish your tool box is completely up to you. I used a nail set to set any nails that were not set by the nail gun and filed all holes with would filler and let dry. I then sanded the box starting with 120 grit and finished with 220 grit. I have not decided yet if I will paint or stain my box.

This was my first wood project and in some ways it was more than I expected. Looking back it was not all that hard but a lot of things to think about. In the end, it was fun to build and something I can use and remember my first project.