Ridgid toolboxes... and fixing the sadness #7: A tray, and finding a new way to secure the handles

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Blog entry by Tony Ennis posted 07-30-2017 11:06 PM 908 reads 0 times favorited 1 comment Add to Favorites Watch
« Part 6: omg handles Part 7 of Ridgid toolboxes... and fixing the sadness series Part 8: Basic construction is almost complete »

Now I have two more handle assemblies to finish.

The handle material was pretty much beat up. I scrapped both. I pillaged a handle from the next part of the project and made a new one. It would have taken forever to salvage the old ones.

I was pretty unhappy with my low-rent blacksmithing. So instead of flattening the ends, my new idea was to get a piece of 16 gauge steel and make retainer washers. These would be super glued to the ends of the handles. Like the flattened ends, they would not pull through the keeper’s 1/4” hole.

Making 4 little parts from a sheet of scrap was certainly doable, and I got to the point that I could almost fit one into the hole in the tray side. But it was so hard to hold the retainer and hard to see. It was no fun at all.

With this in mind, I reassembled my metal lathe. It’s been apart for a while. I had to make a stepped woodruff key for the headstock. So I spent a few hours fitting the new key with a file and reassembling the lathe.

Using the lathe, making the retainers was not hard at all. I turned a rod down to .3”, then drilled a 3/16” hole down the length. Finally, I hacksawed the washers off. I was pleased they were all within .012” thickness of each other.

Then I super-glued these to the ends of the handles. Somewhat more professional looking, I think…

Note the left leg in that picture. That black stuff is Sharpie from my layout efforts. It won’t affect the super glue, right? Wrong. I was able to pull the retainer off with my fingers. I cleaned the washer and handle with acetone and tried again.

I need to do some fitting on these new-style handles. It’s more important that the bends in the handles be square since the retainers fill up a lot more of the hole in the tray ends. Once the fitting is done, I should be able to glue up the thick tray.

In other news, here’s the thin tray I glued up yesterday.

This tray is intended for chisels, pliers, and the like. It is ready for dividers and paint.

-- Tony

1 comment so far

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91 posts in 879 days

#1 posted 08-24-2017 08:25 PM

Simple. Elegant. Effective.
What more can you ask for?

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