The No. 801 catalog pics provide overall dimensions, so between those and the build methodology of the No. 888 that I have in-shop, I’m pretty confident that what I’m making can be pretty true to the original. The biggest issue I could identify was hardware. Finding the right metal handle was everything at first, because I was able to move on from there with a sense of confidence in my ability to build a reasonable facsimile of the original. I knew the handle was metal, and that all wood was less than ¾” in thickness. So the base of the handle had to be the right fit.
If you’ve read any of my blogs on LJs, you’ll know I tend to keep things around for a very, very long time in the hopes of someday finding a use for them. The handle I ended up using fits that model. It was painted a bright bluish green, but the base was single-screw and pretty narrow. Folks, we have a winner.
I created the center spar pretty quick after finding the handle, put the two together, then let the project sit for several weeks. Everyone does that, right? :-)
So yeah, I have wood identified to use and it’s scrap wood. Pallet wood, actually, that I ran through the Alien Head planer when I first got that tool and wanted to play with it. It’s pine, somewhat reddish in tint, like a doug fir but who knows for sure. The stuff is essentially clear of knots, though, and less than ¾” thick. After a bit of grain pattern matching and width checks, I glued up pieces that would become the sides and ends then put the project aside for several more weeks. What got me to walk away was ultimately the same thing that got me back to the build (aside from clearing a couple other projects): Hinges. I couldn’t find what I wanted, even with posts on LJs and OldTools. I did, however, find a pair of hinges from Lee Valley in the drawer that were purchased originally for the tool chest but not used. I think they’ll do, he said to himself.
Hardware is, well, Hard!
Title says it all. I had the flathead, slotted screws needed to attached the bottom to the carcase (per the original), but needed round head screws (slotted, of course) to secure the side boards to the center spar. That same screw type could server as the posts for the lid’s securing hooks (oh, I need to find those too), but short screws were needed to attach the hinges to the sides and each lid.
The hinges, as previously mentioned, came from Lee Valley but required some attention with the Dremmel-like tool I’ve had but rarely used before now.
The brass screws came from a local True Value, and the bright screws came from Menard’s (or vise versa, I don’t remember anymore).
Despite being a hand tool repository, the build itself included almost exclusive use of stationary power tools (band saw, RAS, table saw). That said, all final finishes are the result of hand planing with the exception of the rabbets done to the underside of the lids.
The lid material is white oak, salvaged from the folding card table project blogged here on LJs. It was also run through the Alien Head Planer (have I mentioned lately how awesome that tool is?) and rabetted to sit nicely on the carcase.
I won’t go into detail on the sliding tool tray, but it was built as well.
Main spar reinforced with screws through each end cap.
I did some chiseling of the lids and sides to ensure the hinges installed flush to each
then used the G-P tool handle awl bit to prep for screws. Before long, all hardware was in place and the box was essentially complete!
That’s all for now, the final finishing is next! As always, thanks for looking.
-- Don't anthropomorphize your handplanes. They hate it when you do that. -- OldTools Archive --