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Stanley #801 Build

30K views 56 replies 18 participants last post by  PourWhiskey 
#1 ·
Inspiration and Research

Initial Motivation

I don't remember being smitten with these house-shaped toolboxes at first sight, but over the years they've proven to be one of those things that got more detailed attention with every interwebz run-in (ebay and the OldTools list, mostly). An early pic of one I noticed:



Then one appeared on der Leachmeister's List and I jumped in (top image below); a No. 888 was soon in my shop.

The Search

As is typical, my example was missing the inside (sliding) tool holder. That was an easy enough thing to make, but I lacked a clear idea as to general dimensions. A search of the OldTools Archive told me there were several iterations of the No. 888, but specifics were lacking. To the LJ Tool Boxes thread I went, and in short order catalog pictures were put up of not only the No. 888, but catalog pics of all four tool configurations of the 888 (A, B, C and D) as well as pics of Stanley's other House Tool Box, the No. 801. The bug was fed.

After making a sliding holder for the No. 888,



I was dead set on a No. 801 reproduction / copy build. That's all for now, thanks for looking.

 

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#2 ·
Inspiration and Research

Initial Motivation

I don't remember being smitten with these house-shaped toolboxes at first sight, but over the years they've proven to be one of those things that got more detailed attention with every interwebz run-in (ebay and the OldTools list, mostly). An early pic of one I noticed:

Musical instrument Wood Folk instrument Gas String instrument


Then one appeared on der Leachmeister's List and I jumped in (top image below); a No. 888 was soon in my shop.

The Search

As is typical, my example was missing the inside (sliding) tool holder. That was an easy enough thing to make, but I lacked a clear idea as to general dimensions. A search of the OldTools Archive told me there were several iterations of the No. 888, but specifics were lacking. To the LJ Tool Boxes thread I went, and in short order catalog pictures were put up of not only the No. 888, but catalog pics of all four tool configurations of the 888 (A, B, C and D) as well as pics of Stanley's other House Tool Box, the No. 801. The bug was fed.

After making a sliding holder for the No. 888,

Wood Floor Rectangle Wood stain Plank


I was dead set on a No. 801 reproduction / copy build. That's all for now, thanks for looking.

Font Material property Parallel Paper Paper product
I understand the aesthetic appeal and imagine their utility matches in caliber. Your affinity for vintage and refurbishing has supplied me with tons of reading/viewing entertainment, thank you Smitty!
 

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#3 ·
Inspiration and Research

Initial Motivation

I don't remember being smitten with these house-shaped toolboxes at first sight, but over the years they've proven to be one of those things that got more detailed attention with every interwebz run-in (ebay and the OldTools list, mostly). An early pic of one I noticed:

Musical instrument Wood Folk instrument Gas String instrument


Then one appeared on der Leachmeister's List and I jumped in (top image below); a No. 888 was soon in my shop.

The Search

As is typical, my example was missing the inside (sliding) tool holder. That was an easy enough thing to make, but I lacked a clear idea as to general dimensions. A search of the OldTools Archive told me there were several iterations of the No. 888, but specifics were lacking. To the LJ Tool Boxes thread I went, and in short order catalog pictures were put up of not only the No. 888, but catalog pics of all four tool configurations of the 888 (A, B, C and D) as well as pics of Stanley's other House Tool Box, the No. 801. The bug was fed.

After making a sliding holder for the No. 888,

Wood Floor Rectangle Wood stain Plank


I was dead set on a No. 801 reproduction / copy build. That's all for now, thanks for looking.

Font Material property Parallel Paper Paper product
Have you ever considered that you were born a hundred years too late?
 

Attachments

#4 ·
Inspiration and Research

Initial Motivation

I don't remember being smitten with these house-shaped toolboxes at first sight, but over the years they've proven to be one of those things that got more detailed attention with every interwebz run-in (ebay and the OldTools list, mostly). An early pic of one I noticed:

Musical instrument Wood Folk instrument Gas String instrument


Then one appeared on der Leachmeister's List and I jumped in (top image below); a No. 888 was soon in my shop.

The Search

As is typical, my example was missing the inside (sliding) tool holder. That was an easy enough thing to make, but I lacked a clear idea as to general dimensions. A search of the OldTools Archive told me there were several iterations of the No. 888, but specifics were lacking. To the LJ Tool Boxes thread I went, and in short order catalog pictures were put up of not only the No. 888, but catalog pics of all four tool configurations of the 888 (A, B, C and D) as well as pics of Stanley's other House Tool Box, the No. 801. The bug was fed.

After making a sliding holder for the No. 888,

Wood Floor Rectangle Wood stain Plank


I was dead set on a No. 801 reproduction / copy build. That's all for now, thanks for looking.

Font Material property Parallel Paper Paper product
Thanks for riding along, Tony!

T'sup, Yo? Born to late? No way!
 

Attachments

#5 ·
Inspiration and Research

Initial Motivation

I don't remember being smitten with these house-shaped toolboxes at first sight, but over the years they've proven to be one of those things that got more detailed attention with every interwebz run-in (ebay and the OldTools list, mostly). An early pic of one I noticed:

Musical instrument Wood Folk instrument Gas String instrument


Then one appeared on der Leachmeister's List and I jumped in (top image below); a No. 888 was soon in my shop.

The Search

As is typical, my example was missing the inside (sliding) tool holder. That was an easy enough thing to make, but I lacked a clear idea as to general dimensions. A search of the OldTools Archive told me there were several iterations of the No. 888, but specifics were lacking. To the LJ Tool Boxes thread I went, and in short order catalog pictures were put up of not only the No. 888, but catalog pics of all four tool configurations of the 888 (A, B, C and D) as well as pics of Stanley's other House Tool Box, the No. 801. The bug was fed.

After making a sliding holder for the No. 888,

Wood Floor Rectangle Wood stain Plank


I was dead set on a No. 801 reproduction / copy build. That's all for now, thanks for looking.

Font Material property Parallel Paper Paper product
Smitty,

I would like to get a copy of the high resolution picture showing the Stanley No. 444 dovetail detail dimensions for various thicknesses of wood. You mentioned it in your Lumberjack's 3-part discussion on the Stanley 444. If you could send it to davenj@penn.com I would greatly appreciate it. I have recently acquired a Stanley 444 and I am trying to figure out how to set it up. I have seen various low resolution versions of the diagram online but none are readable.
 

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#6 ·
Design / Build

Definition, Staging
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 Âľ" 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.

Wood Table Rectangle Hardwood Gas


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 Âľ" 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.

Font Transparency Comfort food


Wood Knife Blade Hunting knife Tool


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.

Wood Handgun holster Wood stain Hardwood Everyday carry


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).

The Build!
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.

Wood Tool Engineering Machine Machine tool


Wood Bumper Gas Hardwood Machine


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.

Wood Rectangle Floor Hardwood Wood stain


Wood Tool Workbench Table Hardwood


Wood Bumper Gas Automotive exterior Thickness planer


I won't go into detail on the sliding tool tray, but it was built as well.

Musical instrument Wood Keyboard Hardwood Wood stain


Main spar reinforced with screws through each end cap.

Wood Table Hardwood Gas Wood stain


I did some chiseling of the lids and sides to ensure the hinges installed flush to each

Wood Rectangle Hardwood Wood stain Automotive exterior


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!

Wood Musical instrument Wood stain Hardwood Flooring


That's all for now, the final finishing is next! As always, thanks for looking.
 

Attachments

#7 ·
Design / Build

Definition, Staging
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 Âľ" 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.

Wood Table Rectangle Hardwood Gas


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 Âľ" 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.

Font Transparency Comfort food


Wood Knife Blade Hunting knife Tool


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.

Wood Handgun holster Wood stain Hardwood Everyday carry


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).

The Build!
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.

Wood Tool Engineering Machine Machine tool


Wood Bumper Gas Hardwood Machine


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.

Wood Rectangle Floor Hardwood Wood stain


Wood Tool Workbench Table Hardwood


Wood Bumper Gas Automotive exterior Thickness planer


I won't go into detail on the sliding tool tray, but it was built as well.

Musical instrument Wood Keyboard Hardwood Wood stain


Main spar reinforced with screws through each end cap.

Wood Table Hardwood Gas Wood stain


I did some chiseling of the lids and sides to ensure the hinges installed flush to each

Wood Rectangle Hardwood Wood stain Automotive exterior


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!

Wood Musical instrument Wood stain Hardwood Flooring


That's all for now, the final finishing is next! As always, thanks for looking.
Good build Smitty. Now you need to find a SweetHeart emblem to complete it. :)
 

Attachments

#19 ·
Finishing

The UnBuild!

Time to take it apart for aging and finishing. Brasses are staying as they are, but the zinc-coated screws go into vinegar, my first experiment with that process. Going in:

Wood Serveware Automotive tire Tableware Circle


And returning from a two day dip:

Brown Sleeve Linens Pattern Stitch


The box itself needed color in the meantime. Original boxes were darkly stained hardwood (No. 888) or black walnut (No. 801). Well, already missed to walnut boat (oak and pine for me), so dark stain it is. Did some shopping in the Minwax aisle of the local hardware store and decided on English Chestnut. Thought briefly about taping off the interior from the stain because a lighter interior means better visibility for the tools inside. Then decided not to. Two coats of stain applied and allowed to thoroughly dry.

Wood Hardwood Composite material Wood stain Gas


Then a coat of 3-2-1 wiping mix. After the first coat, though, added a bit of bling; I took a picture of the SW badge on my No. 888, printed it in color, and placed the cut-out 'badge' on the lid of the once-poly'd box.

Wood Rectangle Wood stain Hardwood Font


I think it's a nice enough addition. An admission it's not original, but a copy. And to me it looks good.

Table Furniture Wood Drawer Chest of drawers


Completion

Here's the result, all screws in place, lids done, etc. etc.

Plane Wood Table Block plane Hardwood


And next to the No. 888:

Wood Table Gas Hardwood Classic


The tool box holds a couple of Stanley bench planes (S5 and S4), along with a few other things. I'm thinking of outfitting it with a set of tools for my oldest son, who will be moving into his first non-college apartment later this year. A fun build, thanks for looking!
 

Attachments

#20 ·
Finishing

The UnBuild!

Time to take it apart for aging and finishing. Brasses are staying as they are, but the zinc-coated screws go into vinegar, my first experiment with that process. Going in:

Wood Serveware Automotive tire Tableware Circle


And returning from a two day dip:

Brown Sleeve Linens Pattern Stitch


The box itself needed color in the meantime. Original boxes were darkly stained hardwood (No. 888) or black walnut (No. 801). Well, already missed to walnut boat (oak and pine for me), so dark stain it is. Did some shopping in the Minwax aisle of the local hardware store and decided on English Chestnut. Thought briefly about taping off the interior from the stain because a lighter interior means better visibility for the tools inside. Then decided not to. Two coats of stain applied and allowed to thoroughly dry.

Wood Hardwood Composite material Wood stain Gas


Then a coat of 3-2-1 wiping mix. After the first coat, though, added a bit of bling; I took a picture of the SW badge on my No. 888, printed it in color, and placed the cut-out 'badge' on the lid of the once-poly'd box.

Wood Rectangle Wood stain Hardwood Font


I think it's a nice enough addition. An admission it's not original, but a copy. And to me it looks good.

Table Furniture Wood Drawer Chest of drawers


Completion

Here's the result, all screws in place, lids done, etc. etc.

Plane Wood Table Block plane Hardwood


And next to the No. 888:

Wood Table Gas Hardwood Classic


The tool box holds a couple of Stanley bench planes (S5 and S4), along with a few other things. I'm thinking of outfitting it with a set of tools for my oldest son, who will be moving into his first non-college apartment later this year. A fun build, thanks for looking!
Tremendous job, Smitty. Great combination of attention to detail and willingness to push through. Is the SW on the 888 a sticker or plate?
 

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