Tool box for the tool box #2: Prototype # 2

Finally got a table saw and thickness planer, and had to use them. Spent one whole day one assembly and setup of the two, then went to the Borg for lumber. Got some nice Poplar and a decent sheet of 1/2” ply. Then I set to work. Rough cross cut, joint, edge joint, thickness plane, rip, edge glue, thickness plane, edge joint, rip to final width, cross cut to length. Hand cut mortise and tenons. Hand cut dovetails. Fit, refit. Rout stopped dadoes for bottom. Cut curve and slot for handle. Cut plywood bottom. Time for glue up. Rush, rush, rush. Find out the bottom is a little too wide, find out the handle is a little too long. End result, functional but not too pretty. The ends are bowed slightly due to the center part being too long. How did this happen? I used the stock to mark for the tenon length, and then set my marking gage to layout the dovetails. Used two different “tools” to lay out the same thickness. “D-oh” comes to mind. And the bottom? Relied on a measurement (which was too close anyhow for a “floating panel”) instead of fitting the bottom to the piece. So my buddy came over last night, and brought his truck. He was really pleased with the results, since he couldn’t see the huge gaps everywhere like the guy who built it can. We test fit it in his tool box, and (thank the woodworking gods) we decided (with my steering since it wasn’t that much lumber and not expensive at all) that is was too big to get it in and out easy. “Whew”. Now the wife has already decided how she can use the one that is built, (in an inconspicuous part of the house), and I have the chance to remake the one for my buddy. I also got the measurements for the “sliding tray” that he wants me to make to replace the plastic one that cracked and broke long ago. I will try to add some pics later, but now its time to go get more wood, “working on grain matching this time too” and give it another go. Hope it comes off better this time, with many good lessons learned.

-- Jimmy, Oklahoma "It's a dog-eat-dog world, and I'm wearing milkbone underwear!"