Ok, two coats of varnish on the chest, and rubbed out. Picked up a 1×10 pine scrap. Tray that is in the back is….ok, but could use one I can lift out and haul stuff around in. Measured the inside available area. Just about 25" long. Hmmm, a backsaw's tote sticks upa bit, so things got a little narrower. Measure the plank, an UGLY one at that
Figured I could get at least three 25" long slabs out of it. Clamped the plank to the bench, marked a line, and tried to cut a straight line with the circular saw. eh, not quite. Set up to rip a piece to the correct width
The jig is an oldie, made as a fence for a Job Site tablesaw. measured over to allow for the width of the sole of the saw, draw a line, clamp the fence to it. Makes a nice straight line of a rip cut, IF one marks the line right. Needed two boards 3-1/2 by 25" long. Needed two at just under 6-1/2 long to go between them. Used a Wards #78 to make rebates on some of the sides, all four edges on the bottom plank. It is 6-1/2 wide by 25". Rebates are 3/4 wide by 3/8" deep.
Installed the long sides into their rebates with glue and screws. Found out, while making shallow counter-bores for the screws, that a 3/8" Forstner drill bit is not a good tool to trim a thumbnail with. Needed to move a board just a hair, and the bit caught the thumbnail. No blood, though, sorry.
Now, the short end pieces. To house a central handle for the tote, I needed a couple stopped dados. one on each end. Laid out a 3" high by 3/4" wide, by 3/8" deep dado.
Had to make sure the other piece was a mirror image, so they would line up. Just the old MK II eyeball gauge to find a place close to the center. Backsaw to saw the waste a bit, then a bunch of chisel work to get things flat in there. WHEW!. Screwed ONE end piece into it's new home. Needed to find the exact length for the handle. Used a sabresaw to cut out the main parts of the handle. Finger holes…..ah, maybe I can trust a larger Forstner bit? Got out an 1-3/8" one, drill a few overlapping holes, and smoothed things out a bit, thumbnail inttact, this time. Chucked up a 3/8" round-over bit into the router. And, without snapping the bit this time, rounded all the edges on the handle. Installed the handle into the tote, added the other end piece, screwed things into place. Now it is ready to be loaded up.
Take a good look, this is about the only time it will ever be empty, again. Placed the tote in to the Tool Chest
Well, well, where did those tools come from? Anyway, even the lid will close, too
Still have to find a length of chain to keep the lid from going to far over, but, I think it is DONE, for now
Thanks for following along…....