Just a simple little box...

bandit571 said:

start up.

Although the Stanley 45 is just about all cleaned and shiny, that box is just about a lost cause….way too many cracks, a repair used the wrong wood. Sooo, I went out and bought some 1/2" x 5-1/2" Poplar. about 5' of it.

Laid out a few crosscuts. two to make the sides of a new box, and two for the ends. An older Sears Craftsman " Special saw" was taken down from the hook, a little wax of the teeth, cuts were done. I clamped up the two matching parts, and ran a plane on the end grain, just to even them up….

Ok, laid out some other toys…er…TOOLS

Including that fancy marking knife. Pencil was to make the lines a bit easier for me to see, as there will be a LOT of them. That mortise chisel had another use to it…it laid out the spacing that was going on.

Along with the marking knife, I used a marking gauge to set how deep to cut….then dragged out another saw, and waxed it up…we had work to do..

Lots of lines to cut. Set up two side pieces at a time, do one end, then the other…

The chisel set the spacing, I just had to chop out the waste. Chisel and mallet..

But I was only chopping one end at a time. I used the knifed line to register the chisel, a few whacks with the mallet. Many of thos little chunks had a habit of flying up and out, right at me. Once the sides were chopped, I laid out which side met which end at which corner. I had a "V" across the "Top" of both the sides and ends, the vwent across both sides and both ends Then I marked which was the inside…

Used one end of a side to lay out the cuts, and waste on one matching end piece. Repeat all the cuts and chops, but, was only doing ONE end piece at a time. I can then work my way around, going corner to corner.

I soon had one corner ready for a test fit..

Got it to fit halfway decent, and called it a night. After I get the other corners done, plan is to cut a few grooves. need them for the top and bottom panels, and a pair of special grooves. There will also be a pair of very narrow dados. as there will be a storage area for bits. As to what I'll be cutting all them grooves with?

Might have just the plane for that sort of thing…stay tuned, we be just starting out…

Click to expand...

bandit571 said:

start up.

Although the Stanley 45 is just about all cleaned and shiny, that box is just about a lost cause….way too many cracks, a repair used the wrong wood. Sooo, I went out and bought some 1/2" x 5-1/2" Poplar. about 5' of it.

Laid out a few crosscuts. two to make the sides of a new box, and two for the ends. An older Sears Craftsman " Special saw" was taken down from the hook, a little wax of the teeth, cuts were done. I clamped up the two matching parts, and ran a plane on the end grain, just to even them up….

Ok, laid out some other toys…er…TOOLS

Including that fancy marking knife. Pencil was to make the lines a bit easier for me to see, as there will be a LOT of them. That mortise chisel had another use to it…it laid out the spacing that was going on.

Along with the marking knife, I used a marking gauge to set how deep to cut….then dragged out another saw, and waxed it up…we had work to do..

Lots of lines to cut. Set up two side pieces at a time, do one end, then the other…

The chisel set the spacing, I just had to chop out the waste. Chisel and mallet..

But I was only chopping one end at a time. I used the knifed line to register the chisel, a few whacks with the mallet. Many of thos little chunks had a habit of flying up and out, right at me. Once the sides were chopped, I laid out which side met which end at which corner. I had a "V" across the "Top" of both the sides and ends, the vwent across both sides and both ends Then I marked which was the inside…

Used one end of a side to lay out the cuts, and waste on one matching end piece. Repeat all the cuts and chops, but, was only doing ONE end piece at a time. I can then work my way around, going corner to corner.

I soon had one corner ready for a test fit..

Got it to fit halfway decent, and called it a night. After I get the other corners done, plan is to cut a few grooves. need them for the top and bottom panels, and a pair of special grooves. There will also be a pair of very narrow dados. as there will be a storage area for bits. As to what I'll be cutting all them grooves with?

Might have just the plane for that sort of thing…stay tuned, we be just starting out…

Click to expand...

bandit571 said:

start up.

Although the Stanley 45 is just about all cleaned and shiny, that box is just about a lost cause….way too many cracks, a repair used the wrong wood. Sooo, I went out and bought some 1/2" x 5-1/2" Poplar. about 5' of it.

Laid out a few crosscuts. two to make the sides of a new box, and two for the ends. An older Sears Craftsman " Special saw" was taken down from the hook, a little wax of the teeth, cuts were done. I clamped up the two matching parts, and ran a plane on the end grain, just to even them up….

Ok, laid out some other toys…er…TOOLS

Including that fancy marking knife. Pencil was to make the lines a bit easier for me to see, as there will be a LOT of them. That mortise chisel had another use to it…it laid out the spacing that was going on.

Along with the marking knife, I used a marking gauge to set how deep to cut….then dragged out another saw, and waxed it up…we had work to do..

Lots of lines to cut. Set up two side pieces at a time, do one end, then the other…

The chisel set the spacing, I just had to chop out the waste. Chisel and mallet..

But I was only chopping one end at a time. I used the knifed line to register the chisel, a few whacks with the mallet. Many of thos little chunks had a habit of flying up and out, right at me. Once the sides were chopped, I laid out which side met which end at which corner. I had a "V" across the "Top" of both the sides and ends, the vwent across both sides and both ends Then I marked which was the inside…

Used one end of a side to lay out the cuts, and waste on one matching end piece. Repeat all the cuts and chops, but, was only doing ONE end piece at a time. I can then work my way around, going corner to corner.

I soon had one corner ready for a test fit..

Got it to fit halfway decent, and called it a night. After I get the other corners done, plan is to cut a few grooves. need them for the top and bottom panels, and a pair of special grooves. There will also be a pair of very narrow dados. as there will be a storage area for bits. As to what I'll be cutting all them grooves with?

Might have just the plane for that sort of thing…stay tuned, we be just starting out…

Click to expand...

bandit571 said:

start up.

Although the Stanley 45 is just about all cleaned and shiny, that box is just about a lost cause….way too many cracks, a repair used the wrong wood. Sooo, I went out and bought some 1/2" x 5-1/2" Poplar. about 5' of it.

Laid out a few crosscuts. two to make the sides of a new box, and two for the ends. An older Sears Craftsman " Special saw" was taken down from the hook, a little wax of the teeth, cuts were done. I clamped up the two matching parts, and ran a plane on the end grain, just to even them up….

Ok, laid out some other toys…er…TOOLS

Including that fancy marking knife. Pencil was to make the lines a bit easier for me to see, as there will be a LOT of them. That mortise chisel had another use to it…it laid out the spacing that was going on.

Along with the marking knife, I used a marking gauge to set how deep to cut….then dragged out another saw, and waxed it up…we had work to do..

Lots of lines to cut. Set up two side pieces at a time, do one end, then the other…

The chisel set the spacing, I just had to chop out the waste. Chisel and mallet..

But I was only chopping one end at a time. I used the knifed line to register the chisel, a few whacks with the mallet. Many of thos little chunks had a habit of flying up and out, right at me. Once the sides were chopped, I laid out which side met which end at which corner. I had a "V" across the "Top" of both the sides and ends, the vwent across both sides and both ends Then I marked which was the inside…

Used one end of a side to lay out the cuts, and waste on one matching end piece. Repeat all the cuts and chops, but, was only doing ONE end piece at a time. I can then work my way around, going corner to corner.

I soon had one corner ready for a test fit..

Got it to fit halfway decent, and called it a night. After I get the other corners done, plan is to cut a few grooves. need them for the top and bottom panels, and a pair of special grooves. There will also be a pair of very narrow dados. as there will be a storage area for bits. As to what I'll be cutting all them grooves with?

Might have just the plane for that sort of thing…stay tuned, we be just starting out…

Click to expand...

bandit571 said:

start up.

Although the Stanley 45 is just about all cleaned and shiny, that box is just about a lost cause….way too many cracks, a repair used the wrong wood. Sooo, I went out and bought some 1/2" x 5-1/2" Poplar. about 5' of it.

Laid out a few crosscuts. two to make the sides of a new box, and two for the ends. An older Sears Craftsman " Special saw" was taken down from the hook, a little wax of the teeth, cuts were done. I clamped up the two matching parts, and ran a plane on the end grain, just to even them up….

Ok, laid out some other toys…er…TOOLS

Including that fancy marking knife. Pencil was to make the lines a bit easier for me to see, as there will be a LOT of them. That mortise chisel had another use to it…it laid out the spacing that was going on.

Along with the marking knife, I used a marking gauge to set how deep to cut….then dragged out another saw, and waxed it up…we had work to do..

Lots of lines to cut. Set up two side pieces at a time, do one end, then the other…

The chisel set the spacing, I just had to chop out the waste. Chisel and mallet..

But I was only chopping one end at a time. I used the knifed line to register the chisel, a few whacks with the mallet. Many of thos little chunks had a habit of flying up and out, right at me. Once the sides were chopped, I laid out which side met which end at which corner. I had a "V" across the "Top" of both the sides and ends, the vwent across both sides and both ends Then I marked which was the inside…

Used one end of a side to lay out the cuts, and waste on one matching end piece. Repeat all the cuts and chops, but, was only doing ONE end piece at a time. I can then work my way around, going corner to corner.

I soon had one corner ready for a test fit..

Got it to fit halfway decent, and called it a night. After I get the other corners done, plan is to cut a few grooves. need them for the top and bottom panels, and a pair of special grooves. There will also be a pair of very narrow dados. as there will be a storage area for bits. As to what I'll be cutting all them grooves with?

Might have just the plane for that sort of thing…stay tuned, we be just starting out…

Click to expand...

bandit571 said:

The other corners get their turn..

Well, had a heart monitor on for a few days ( taped the electrodes on, and they got ripped off…OW!) Did a short rust hunt. Couple of coping saws needed new blades…spent $2 on each saw. Already had the blades.

Stopped at the Green Borg ( Menards) and got a few pieces of hardware. new brass hinges, a new "Olde Brass" Latch, and a few bags of brass screws…..NOT phillips headed ones, either. I got the ones with the slotted, oval heads.

Anyway…..got back to chopping the finger joints. Laid the next two sides end to end, like they will be in the box. Marked across for the waste areas, this time. Hand is still crampy from the handsaw part of this, soooo, we do have a bandsaw sitting right beside the bench.

Same as the other day, I used the mortise chisel to pop the waste out…WARNING: Be sure to wear safety glasses! Them little chunks will fly straight back at you. Had quite a few bounce off of mine. Seemed that each corner I completed to night looked a bit better than the last one. Two corner s done, might as well keep trucking along…..

Finally got all four corners done!!!! Without a single miss-cut anywhere. Now that I had a square looking thing on my bench, I could measure for a bottom panel. Had some thin plywood….old chisel rack….tore it about to get the less than square panel out. Had to pull a few nails, too. Found two edges that were CLOSE to being square..meh. Marked a line, ran it through the bandsaw. Checked the cut…ok, clamp the panel in the vise, run a plane along that edge until it is straight. Then, worked my way around to the next side.

Got end and side square…marked out the size I needed to fit in the bottom of the box…repeat the above cut, check, plane, check. Set up the Wards #78 to cut a shallow rebate all the way around. Then checked for a fit…had to widen the rebate just a smidge…finally fits. Left it sitting there

Finally, I set up another plane. Later, I start cutting grooves. Have ones for the bottom to fit into, and an inside and an outside groove, so the lid will seperate from the box, but have a lip around the edges as a dust seal…..Got just the right size cutter installed…needed a few changes , though..

The short rods were too short, had to install the long rods. Needed the cam rest, as this thing may get a bit tippy. Slider section is about all the way in. I didn't let the nickers down, don't need them for with the grain cuts.

Lets see…..got four corners milled up (whew..) got the bottom panel milled for a groove. Got things set up for the 45 to do it's thing….need to make a panel for the top of the lid…..then maybe a glue up or 10??? Stay tuned, starting to get a bit scary….

Click to expand...

bandit571 said:

Grooves, a top, and more grooves

Well, was able to sneak downstairs to the shop for a few minutes this morning….figured out how to make a skinny board get wide enough to make the top of this box. Lengthwise, was twice as long as I needed, no biggie. Mark a line at the mid point, square it (almost) across, and cut the line. Then, I need to know how wide the panel needed to be…..a few marks later, a rip cut, and I had two pieces ready to glue up. Spread a bit of glue, rub the joint back and forth a couple times ( while I dug up all four bench dogs) clamped the panel flat to the bench, and used the end vise and the dogs to keep things clamped up. The boss had errands to run…time for the glue to cure.

Came back home, it took awhile to get back in the shop…..finally was able to sneak away and work on the top to be.

Old #900 plane to joint the edges. Was trying to get all corners square, and the edges straight. Finally could lay that aside. Decided to mill a rebate for the panel to sit in. Reset the 45. Got one side piece, added a few drywall screws to keep things from sliding down the bench, or worse. Ran the plane a bit, checking for fit with the panel..

the bad part was, I had to turn the fence over, to get that last bit of depth. The cam came in handy, but the fence adjust bolt wanted to rub on the panel. Got all four rebates done, reset things a bit. Needed a groove around the out side of the box, to form a lip to seal the box…..Cut down about half way through, and put the sides back together as I got things done..

Even had the panel for the lid sitting there…next came the tricky part, I needed a groove around the box on the inside, just above the outside one. Had to go over each side piece, marking both the box and the lid sections.
Reset the plane, again..

Fought the fence again, got to the point where it was just a sliver holding the two pieces together. Trusty old pocket knife to finish the cut. Then another plane worked on a fine tune of the joint..

It was easier to put the part in a vise and use the shoulder plane. I kept checking the fit..

Getting there. Got all four sides done, then a final fitting of the top and and the top panel. Then a glue up..

let this set overnight. later, I'll go back, fill all the voids, and sand things smooth. Still have to do the bottom panel. Might be some other items to do inside the box, we'll see. Stay tuned

Click to expand...

bandit571 said:

Grooves, a top, and more grooves

Well, was able to sneak downstairs to the shop for a few minutes this morning….figured out how to make a skinny board get wide enough to make the top of this box. Lengthwise, was twice as long as I needed, no biggie. Mark a line at the mid point, square it (almost) across, and cut the line. Then, I need to know how wide the panel needed to be…..a few marks later, a rip cut, and I had two pieces ready to glue up. Spread a bit of glue, rub the joint back and forth a couple times ( while I dug up all four bench dogs) clamped the panel flat to the bench, and used the end vise and the dogs to keep things clamped up. The boss had errands to run…time for the glue to cure.

Came back home, it took awhile to get back in the shop…..finally was able to sneak away and work on the top to be.

Old #900 plane to joint the edges. Was trying to get all corners square, and the edges straight. Finally could lay that aside. Decided to mill a rebate for the panel to sit in. Reset the 45. Got one side piece, added a few drywall screws to keep things from sliding down the bench, or worse. Ran the plane a bit, checking for fit with the panel..

the bad part was, I had to turn the fence over, to get that last bit of depth. The cam came in handy, but the fence adjust bolt wanted to rub on the panel. Got all four rebates done, reset things a bit. Needed a groove around the out side of the box, to form a lip to seal the box…..Cut down about half way through, and put the sides back together as I got things done..

Even had the panel for the lid sitting there…next came the tricky part, I needed a groove around the box on the inside, just above the outside one. Had to go over each side piece, marking both the box and the lid sections.
Reset the plane, again..

Fought the fence again, got to the point where it was just a sliver holding the two pieces together. Trusty old pocket knife to finish the cut. Then another plane worked on a fine tune of the joint..

It was easier to put the part in a vise and use the shoulder plane. I kept checking the fit..

Getting there. Got all four sides done, then a final fitting of the top and and the top panel. Then a glue up..

let this set overnight. later, I'll go back, fill all the voids, and sand things smooth. Still have to do the bottom panel. Might be some other items to do inside the box, we'll see. Stay tuned

Click to expand...

bandit571 said:

Grooves, a top, and more grooves

Well, was able to sneak downstairs to the shop for a few minutes this morning….figured out how to make a skinny board get wide enough to make the top of this box. Lengthwise, was twice as long as I needed, no biggie. Mark a line at the mid point, square it (almost) across, and cut the line. Then, I need to know how wide the panel needed to be…..a few marks later, a rip cut, and I had two pieces ready to glue up. Spread a bit of glue, rub the joint back and forth a couple times ( while I dug up all four bench dogs) clamped the panel flat to the bench, and used the end vise and the dogs to keep things clamped up. The boss had errands to run…time for the glue to cure.

Came back home, it took awhile to get back in the shop…..finally was able to sneak away and work on the top to be.

Old #900 plane to joint the edges. Was trying to get all corners square, and the edges straight. Finally could lay that aside. Decided to mill a rebate for the panel to sit in. Reset the 45. Got one side piece, added a few drywall screws to keep things from sliding down the bench, or worse. Ran the plane a bit, checking for fit with the panel..

the bad part was, I had to turn the fence over, to get that last bit of depth. The cam came in handy, but the fence adjust bolt wanted to rub on the panel. Got all four rebates done, reset things a bit. Needed a groove around the out side of the box, to form a lip to seal the box…..Cut down about half way through, and put the sides back together as I got things done..

Even had the panel for the lid sitting there…next came the tricky part, I needed a groove around the box on the inside, just above the outside one. Had to go over each side piece, marking both the box and the lid sections.
Reset the plane, again..

Fought the fence again, got to the point where it was just a sliver holding the two pieces together. Trusty old pocket knife to finish the cut. Then another plane worked on a fine tune of the joint..

It was easier to put the part in a vise and use the shoulder plane. I kept checking the fit..

Getting there. Got all four sides done, then a final fitting of the top and and the top panel. Then a glue up..

let this set overnight. later, I'll go back, fill all the voids, and sand things smooth. Still have to do the bottom panel. Might be some other items to do inside the box, we'll see. Stay tuned

Click to expand...

bandit571 said:

Getting close to a finish line, now

But, had quite a bit of work to do first..

Lid came out of the clamps..voids on the ends filled. Gaps filled and sanded. Had one filler piece pop out, back into the clamps it went. Got set up for the bottom rebate, used a Wards 78 to mill it. Had to milled a few grooves to add the cutter storage dividers.

Needed two narrow dados. Thought I'd try the 45 to cut them….

Couldn't get the skates close enough. Could only get one of the spurs to move. Square and marking knife to score four lines, got out the old school tools..

Backsaw, and a narrow chisel. Saw down a bit, and then pop the waste out with the chisel..

Repeat with the other side. Had to backcut some of the finger joints, to get a tighter fit. Finally got the four sides into the clamps….

LOTS of clamps. Had some errands to run, let this mess sit for a while….

Ok, after Supper, I snuck back down to the shop. Got the clamps off…

Cleaned the glue runs off. Time to fit a bottom panel. Had to shorten the panel, and recut a rebate. Finally a bit of glue and some brads..

And sanded things up a bit. Had to cut some extra panels….the ones I thought I'd use for the cutter storage area…too small. Ok, I did have some 3mm thick plywood, just meant I needed four pieces instead of two

Test fit of a cutter, show things were a might deep….added a strip as a floor in each cavity. Then came the fun part…..fitting the lid to the box…..LOTS of shoulder plane and Wards 78 work….finally got the lid to at least sit like the original does. Got the hinges out, and some brass screws..

Even took the time to "clock" the slots of the screws. I also needed a divider glued to the floor of the box..

Not sure why Stanley had this in there, and once again, I needed to double things up. Then needed to install a latch on the front..

I used the screws that came with the latch. Time to load this thing up, to see how it all fits..

All but one cutter in the slots. Trying to find out just how Stanley loaded the rest of the parts..

Finally got them all in there…time to see how this box matches up to the old one…
(Drum Roll…)

Getting there….

The new box is just Poplar…not sure what finish it will get. Stanley PAINTED this one….meh. Might look around for labels, the originals are a bit worn out.

Stay tuned, we are almost done….

Click to expand...

bandit571 said:

Getting close to a finish line, now

But, had quite a bit of work to do first..

Lid came out of the clamps..voids on the ends filled. Gaps filled and sanded. Had one filler piece pop out, back into the clamps it went. Got set up for the bottom rebate, used a Wards 78 to mill it. Had to milled a few grooves to add the cutter storage dividers.

Needed two narrow dados. Thought I'd try the 45 to cut them….

Couldn't get the skates close enough. Could only get one of the spurs to move. Square and marking knife to score four lines, got out the old school tools..

Backsaw, and a narrow chisel. Saw down a bit, and then pop the waste out with the chisel..

Repeat with the other side. Had to backcut some of the finger joints, to get a tighter fit. Finally got the four sides into the clamps….

LOTS of clamps. Had some errands to run, let this mess sit for a while….

Ok, after Supper, I snuck back down to the shop. Got the clamps off…

Cleaned the glue runs off. Time to fit a bottom panel. Had to shorten the panel, and recut a rebate. Finally a bit of glue and some brads..

And sanded things up a bit. Had to cut some extra panels….the ones I thought I'd use for the cutter storage area…too small. Ok, I did have some 3mm thick plywood, just meant I needed four pieces instead of two

Test fit of a cutter, show things were a might deep….added a strip as a floor in each cavity. Then came the fun part…..fitting the lid to the box…..LOTS of shoulder plane and Wards 78 work….finally got the lid to at least sit like the original does. Got the hinges out, and some brass screws..

Even took the time to "clock" the slots of the screws. I also needed a divider glued to the floor of the box..

Not sure why Stanley had this in there, and once again, I needed to double things up. Then needed to install a latch on the front..

I used the screws that came with the latch. Time to load this thing up, to see how it all fits..

All but one cutter in the slots. Trying to find out just how Stanley loaded the rest of the parts..

Finally got them all in there…time to see how this box matches up to the old one…
(Drum Roll…)

Getting there….

The new box is just Poplar…not sure what finish it will get. Stanley PAINTED this one….meh. Might look around for labels, the originals are a bit worn out.

Stay tuned, we are almost done….

Click to expand...

bandit571 said:

Getting close to a finish line, now

But, had quite a bit of work to do first..

Lid came out of the clamps..voids on the ends filled. Gaps filled and sanded. Had one filler piece pop out, back into the clamps it went. Got set up for the bottom rebate, used a Wards 78 to mill it. Had to milled a few grooves to add the cutter storage dividers.

Needed two narrow dados. Thought I'd try the 45 to cut them….

Couldn't get the skates close enough. Could only get one of the spurs to move. Square and marking knife to score four lines, got out the old school tools..

Backsaw, and a narrow chisel. Saw down a bit, and then pop the waste out with the chisel..

Repeat with the other side. Had to backcut some of the finger joints, to get a tighter fit. Finally got the four sides into the clamps….

LOTS of clamps. Had some errands to run, let this mess sit for a while….

Ok, after Supper, I snuck back down to the shop. Got the clamps off…

Cleaned the glue runs off. Time to fit a bottom panel. Had to shorten the panel, and recut a rebate. Finally a bit of glue and some brads..

And sanded things up a bit. Had to cut some extra panels….the ones I thought I'd use for the cutter storage area…too small. Ok, I did have some 3mm thick plywood, just meant I needed four pieces instead of two

Test fit of a cutter, show things were a might deep….added a strip as a floor in each cavity. Then came the fun part…..fitting the lid to the box…..LOTS of shoulder plane and Wards 78 work….finally got the lid to at least sit like the original does. Got the hinges out, and some brass screws..

Even took the time to "clock" the slots of the screws. I also needed a divider glued to the floor of the box..

Not sure why Stanley had this in there, and once again, I needed to double things up. Then needed to install a latch on the front..

I used the screws that came with the latch. Time to load this thing up, to see how it all fits..

All but one cutter in the slots. Trying to find out just how Stanley loaded the rest of the parts..

Finally got them all in there…time to see how this box matches up to the old one…
(Drum Roll…)

Getting there….

The new box is just Poplar…not sure what finish it will get. Stanley PAINTED this one….meh. Might look around for labels, the originals are a bit worn out.

Stay tuned, we are almost done….

Click to expand...

bandit571 said:

Getting close to a finish line, now

But, had quite a bit of work to do first..

Lid came out of the clamps..voids on the ends filled. Gaps filled and sanded. Had one filler piece pop out, back into the clamps it went. Got set up for the bottom rebate, used a Wards 78 to mill it. Had to milled a few grooves to add the cutter storage dividers.

Needed two narrow dados. Thought I'd try the 45 to cut them….

Couldn't get the skates close enough. Could only get one of the spurs to move. Square and marking knife to score four lines, got out the old school tools..

Backsaw, and a narrow chisel. Saw down a bit, and then pop the waste out with the chisel..

Repeat with the other side. Had to backcut some of the finger joints, to get a tighter fit. Finally got the four sides into the clamps….

LOTS of clamps. Had some errands to run, let this mess sit for a while….

Ok, after Supper, I snuck back down to the shop. Got the clamps off…

Cleaned the glue runs off. Time to fit a bottom panel. Had to shorten the panel, and recut a rebate. Finally a bit of glue and some brads..

And sanded things up a bit. Had to cut some extra panels….the ones I thought I'd use for the cutter storage area…too small. Ok, I did have some 3mm thick plywood, just meant I needed four pieces instead of two

Test fit of a cutter, show things were a might deep….added a strip as a floor in each cavity. Then came the fun part…..fitting the lid to the box…..LOTS of shoulder plane and Wards 78 work….finally got the lid to at least sit like the original does. Got the hinges out, and some brass screws..

Even took the time to "clock" the slots of the screws. I also needed a divider glued to the floor of the box..

Not sure why Stanley had this in there, and once again, I needed to double things up. Then needed to install a latch on the front..

I used the screws that came with the latch. Time to load this thing up, to see how it all fits..

All but one cutter in the slots. Trying to find out just how Stanley loaded the rest of the parts..

Finally got them all in there…time to see how this box matches up to the old one…
(Drum Roll…)

Getting there….

The new box is just Poplar…not sure what finish it will get. Stanley PAINTED this one….meh. Might look around for labels, the originals are a bit worn out.

Stay tuned, we are almost done….

Click to expand...