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Figure 1

The Workshop Toolbox
 
Nine drawers of storage in this 2-piece toolbox give you a place for everything

Step 2: Cut all parts to size, according to the Bill of Materials by first ripping all stock to width, then crosscutting to length. Joint 1/32" off each end of pieces A & N to bring them to final dimension (See page 76 in Shopsmith's Power Tool Woodworking for Everyone textbook for the proper technique).

IMPORTANT NOTE: You will notice that the height of the box sides (as shown in the BOX SIDE LAYOUT drawing) is indicated as being 12-1/8" -- and the height of the finished box (as shown in the FRONT LAYOUT drawing) is shown as 12". Both of these dimensions are correct. The additional 1/8" is necessary to allow for the saw kerf when sawing lid from the box in step 17, below.

Step 3: Cut the 3/8" wide by 3/16" deep stop dadoes for the drawer glides (F & R) in the sides (A & N), and partitions (J & T), using a 3/8" router bit in the MARK V Router set-up. See Fig. 1.

NOTE: Dadoes are cuts made across the grain of the wood -- Grooves are cuts made with the grain of the wood.

Next, change to a 1/2" router bit and use the same set-up to rout the 1/2" wide by 1/8" deep stop dadoes in the sides (A) to accept the compartment bottom (G).

Step 4: Cut a 1/8" wide by 1/8" deep stop groove on the upper part of the sides (A). These grooves will accept the front and back faces (B & C). Tip: Use a table saw blade that makes a 1/8" wide kerf to cut these grooves. Chisel the bottom of the groove to depth for the front face (B) See BOX SIDE LAYOUT drawing for detail.

Base Side Layout Front Layout 2 Box Side Layout
Click to Enlarge
Click to Enlarge
Click to Enlarge

 

Cut the 1/8" wide by 1/8" deep dadoes for the tops and bottoms (H,K,S) in the sides (A & N). Cut the 1/8" wide by 1/8" deep grooves at the top and bottom of the front face (B) and the top only of the back face (C).

Cut the grooves in the backs of the sides (A & N) that will accept the (1/8" x 1/8") tongues on the ends of the backs (L & U). The grooves in the box sides (A) are stop grooves, while those in the base sides (N) run from end-to-end.

Complete the groove and rabbet joints in the back edges of the sides (A & N). See BASE SIDE LAYOUT drawing for detail.

Step 5: Form the 1/8" by 1/8" tongues on the ends of parts B, C, H, L, S & U as shown in the exploded view. Next, form a 1/8" x 1/8" tongue along the front top edge of part G. Form a 1/8" x 1/8" tongue along the front and back bottom edges...and across the bottom edge of each end of part K.

 

Continue . . .

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