Ridgid toolboxes... and fixing the sadness #9: The wooden box is done

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Blog entry by Tony Ennis posted 08-06-2017 12:02 AM 735 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 8: Basic construction is almost complete Part 9 of Ridgid toolboxes... and fixing the sadness series Part 10: Analysis paralysis »

I have completed the wooden box except for finishing. I didn’t have a plan and it caught up to me when I tried to mount the handled on the wooden box.

First, the wooden box has a 1/2” x 1/2” lip around it, and this allows it to sit on the original tray’s supports. But that’s not enough meat when I need to drill 3/8” holes for the handle legs. Further, the legs cannot be exposed when the wood box is out of the toolbox. For as surely as the sun will rise tomorrow, they’ll get bent.

So I glued additional plywood to the box. This will house and protect the legs.

What you see there are two pieces of plywood that will house the handle legs. The split down the middle allows the support protruding from the side of the toolbox to reach the lip. Because I had to do this with both sides, and because… clamps, I decided to screw and glue them. So I rummaged around the shop until I found 3/4” wood screws. They are probably 30 years or more old. I measured and drilled pilot holes and even drilled countersinks. Glue and screw and a job well done!

And as I tightened down the last screw, I realized I had not taken into account that the screws could interfere with the handle legs. But only if I happened to put a screw in the wrong place. And of course I did.

I wasn’t undoing it. So now the glue is dried and I’ll eventually have to deal with this screw. First, I don’t need it. These plywood pieces only protect the legs; they carry no load. Second, they are glued on. They aren’t coming off. Third, it’s only a toolbox so a empty countersunk hold is ok, right? Of course it isn’t. I’ll probably cut the screw off and if necessary, CA glue it in place. Let the box’s next owner curse me. /shrug

If I got to do to over again, the three side pieces (lip and two leg protectors) would be cut from a single piece of plywood, and it would be at least 2” deep (like the add-on pieces in the pic) to provide as much glue area as possible for the lip. It would be much much stronger and much simpler.

After all that I got the handles attached. Here we see the box and its trays in place, again with a ‘serving suggestion’ of tools.

And and a close up of the new handles. Note the rounded corner on the wooden box; the corner was catching on a protrusion in the corner of the Ridgid!

Now the wooden box is ready to have its edged broken and to be sanded for painting.

So what’s next is for me to finalize the tools that will be in the box, locate them on their trays, and then glue on dividers to keep tools in their places. So the chisels won’t be touching anything, pliers can be stacked, screwdrivers will nestle.

I have broken the home center mafia’s requirement that I use plywood or 3/4” lumber by resawing a 2×4 to make some 1/4” pieces. These will be sawn into dividers, and and glued down.

-- Tony

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