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Thank you for your purchase from Popular Woodworking.To get more great information about woodworking, please visit our site at www.popularwoodworking.com. Learn about magazines, books, DVDs and more, all focusing on woodworking.POPULAR WOODWORKING BOOKS335P R O J E C TjimstoolboxThis box is patterned after a box Imade several years ago while work-ing in a large production shop. Itholds a surprising amount of tools.(At the time I made the original, I didnt have enough tools to fill halfof the drawers!)One feature deviates a little from traditional cabinetry: The di-vider is attached to the chest only atthe bottom and the back. This makesit possible to put a wide drawer (astandard crosscut handsaw fits in itperfectly) at the top of the chest andstill have smaller drawers below it.The drawers are made using the sametechniques as the drawers for the ten-drawer chest.I made this chest out of a pallet I found in a warehouse. The wood has nail and screw holes in it, but itstill looks neat.335P R O J E C TjimstoolboxThis box is patterned after a box Imade several years ago while work-ing in a large production shop. Itholds a surprising amount of tools.(At the time I made the original, I didnt have enough tools to fill halfof the drawers!)One feature deviates a little from traditional cabinetry: The di-vider is attached to the chest only atthe bottom and the back. This makesit possible to put a wide drawer (astandard crosscut handsaw fits in itperfectly) at the top of the chest andstill have smaller drawers below it.The drawers are made using the sametechniques as the drawers for the ten-drawer chest.I made this chest out of a pallet I found in a warehouse. The wood has nail and screw holes in it, but itstill looks neat.3534 331/2" 12" 101/2" 141/2" 3/4" 1" 32" 1/2" backpanel Cbottom Bside A (2)top Ddivider Edoor Fbase GHJKKLLMNNPP 12"top Ddrawer lock 173/4" 3/4"step 1 After cutting out the parts and as-sembling the back panel C (see the sidebarHow to Assemble a Frame and Panel inproject seven), glue the bottom B to the backpanel. Double-check for squareness.step 2 Cut the drawer grooves in the endsA and the divider E. Use a table saw or arouter mounted in a router table. Be sure toreference the grooves from the bottoms of theparts. Hold the bottoms against the fence.This will ensure that all the grooves will lineup with each other.step 3 Glue and screw the vertical divider Eto the bottom B, and glue it to the center stilein the back panel C (no screws). Double-check that the divider is square to the bottompanel. This panel will stay in position withvery little movement at the front, and thedrawers will work just fine.REFERENCEQUANTITYPARTSTOCKTHICKNESSWIDTHLENGTHA 2 ends pine 34 1012 1412B 1 bottom pine 34 10 3012C 1 back panel pine 12 3012 14122 back C stiles pine 12 214 14121 back C center stile pine 12 214 112 back C rails pine 12 214 272 back C panels pine 316 1258 11D 1 top pine 34 12 3312E 1 divider pine 34 10 1112F 1 door pine 34 32 14382 door F stiles pine 34 214 14382 door F rails pine 34 214 28121 door F panel pine 14 1058 2812G 1 base pine 1 10 312 base G side rails pine 1 2 101 base G front rail pine 1 2 311 base G back rail pine 1 2 27H 1 top drawer pine/ply 134 10 312 drawer H sides pine 12 112 92 drawer H frnts & bcks pine 12 112 307161 drawer H bott plywood 14 10 31J 1 drawer pine/ply 112 10 18142 drawer J sides pine 12 114 92 drawer J frnts & bcks pine 12 114 1711161 drawer J bott plywood 14 10 1814K 2 drawers pine/ply 2 10 18144 drawer K sides pine 12 134 94 drawer K frnts & bcks pine 12 134 1711164 drawer K botts plywood 14 10 1814L 2 drawers pine/ply 214 10 18144 drawer L sides pine 12 2 94 drawer L frnts & bcks pine 12 2 1711162 drawer L botts plywood 14 10 1814M 1 drawer pine/ply 112 10 12122 drawer M sides pine 12 114 92 drawer M frnts & bcks pine 12 114 1115161 drawer M bott plywood 14 10 1212N 2 drawers pine/ply 2 10 12124 drawer N sides pine 12 134 94 drawer N frnts & bcks pine 12 134 1115162 drawer N botts plywood 14 10 1212P 2 drawers pine/ply 214 10 12124 drawer P sides pine 12 2 94 drawer P frnts & bcks pine 12 2 1115162 drawer P botts plywood 14 10 1212h a r d w a r e 1 continuous hinge 316" 112" 32" 1 drawer lockh a r d w a r e 1 continuous hinge 5mm 38mm 813mm 1 drawer lockREFERENCEQUANTITYPARTSTOCKTHICKNESSWIDTHLENGTHA 2 ends pine 19 267 368 B 1 bottom pine 19 254 775C 1 back panel pine 13 775 3682 back C stiles pine 13 57 3681 back C center stile pine 13 57 2792 back C rails pine 13 57 6862 back C panels pine 5 321 279D 1 top pine 19 305 851E 1 divider pine 19 254 292F 1 door pine 19 813 3652 door F stiles pine 19 57 3652 door F rails pine 19 57 7241 door F panel pine 6 270 724G 1 base pine 25 254 7872 base G side rails pine 25 51 2541 base G front rail pine 25 51 7871 base G back rail pine 25 51 686H 1 top drawer pine/ply 45 254 7872 drawer H sides pine 13 38 2292 drawer H frnts & bcks pine 13 38 7731 drawer H bott plywood 6 254 787J 1 drawer pine/ply 38 254 4642 drawer J sides pine 13 32 2292 drawer J frnts & bcks pine 13 32 4561 drawer J bott plywood 6 254 464K 2 drawers pine/ply 51 254 4644 drawer K sides pine 13 45 2294 drawer K frnts & bcks pine 13 45 4562 drawer K botts plywood 6 254 464L 2 drawers pine/ply 57 254 4644 drawer L sides pine 13 51 2294 drawer L frnts & bcks pine 13 51 4562 drawer L botts plywood 6 254 464M 1 drawer pine/ply 38 254 3182 drawer M sides pine 13 32 2292 drawer M frnts & bcks pine 13 32 3031 drawer M bott plywood 6 254 311N 2 drawers pine/ply 51 254 2984 drawer N sides pine 13 45 2294 drawer N frnts & bcks pine 13 45 3032 drawer N botts plywood 6 254 311P 2 drawers pine/ply 57 254 2984 drawer P sides pine 13 51 2294 drawer P frnts & bcks pine 13 51 3032 drawer P botts plywood 6 254 311materials listI N C H E S M I L L I M E T E R SS T E P - B Y- S T E P construction3534 331/2" 12" 101/2" 141/2" 3/4" 1" 32" 1/2" backpanel Cbottom Bside A (2)top Ddivider Edoor Fbase GHJKKLLMNNPP 12"top Ddrawer lock 173/4" 3/4"step 1 After cutting out the parts and as-sembling the back panel C (see the sidebarHow to Assemble a Frame and Panel inproject seven), glue the bottom B to the backpanel. Double-check for squareness.step 2 Cut the drawer grooves in the endsA and the divider E. Use a table saw or arouter mounted in a router table. Be sure toreference the grooves from the bottoms of theparts. Hold the bottoms against the fence.This will ensure that all the grooves will lineup with each other.step 3 Glue and screw the vertical divider Eto the bottom B, and glue it to the center stilein the back panel C (no screws). Double-check that the divider is square to the bottompanel. This panel will stay in position withvery little movement at the front, and thedrawers will work just fine.REFERENCEQUANTITYPARTSTOCKTHICKNESSWIDTHLENGTHA 2 ends pine 34 1012 1412B 1 bottom pine 34 10 3012C 1 back panel pine 12 3012 14122 back C stiles pine 12 214 14121 back C center stile pine 12 214 112 back C rails pine 12 214 272 back C panels pine 316 1258 11D 1 top pine 34 12 3312E 1 divider pine 34 10 1112F 1 door pine 34 32 14382 door F stiles pine 34 214 14382 door F rails pine 34 214 28121 door F panel pine 14 1058 2812G 1 base pine 1 10 312 base G side rails pine 1 2 101 base G front rail pine 1 2 311 base G back rail pine 1 2 27H 1 top drawer pine/ply 134 10 312 drawer H sides pine 12 112 92 drawer H frnts & bcks pine 12 112 307161 drawer H bott plywood 14 10 31J 1 drawer pine/ply 112 10 18142 drawer J sides pine 12 114 92 drawer J frnts & bcks pine 12 114 1711161 drawer J bott plywood 14 10 1814K 2 drawers pine/ply 2 10 18144 drawer K sides pine 12 134 94 drawer K frnts & bcks pine 12 134 1711164 drawer K botts plywood 14 10 1814L 2 drawers pine/ply 214 10 18144 drawer L sides pine 12 2 94 drawer L frnts & bcks pine 12 2 1711162 drawer L botts plywood 14 10 1814M 1 drawer pine/ply 112 10 12122 drawer M sides pine 12 114 92 drawer M frnts & bcks pine 12 114 1115161 drawer M bott plywood 14 10 1212N 2 drawers pine/ply 2 10 12124 drawer N sides pine 12 134 94 drawer N frnts & bcks pine 12 134 1115162 drawer N botts plywood 14 10 1212P 2 drawers pine/ply 214 10 12124 drawer P sides pine 12 2 94 drawer P frnts & bcks pine 12 2 1115162 drawer P botts plywood 14 10 1212h a r d w a r e 1 continuous hinge 316" 112" 32" 1 drawer lockh a r d w a r e 1 continuous hinge 5mm 38mm 813mm 1 drawer lockREFERENCEQUANTITYPARTSTOCKTHICKNESSWIDTHLENGTHA 2 ends pine 19 267 368 B 1 bottom pine 19 254 775C 1 back panel pine 13 775 3682 back C stiles pine 13 57 3681 back C center stile pine 13 57 2792 back C rails pine 13 57 6862 back C panels pine 5 321 279D 1 top pine 19 305 851E 1 divider pine 19 254 292F 1 door pine 19 813 3652 door F stiles pine 19 57 3652 door F rails pine 19 57 7241 door F panel pine 6 270 724G 1 base pine 25 254 7872 base G side rails pine 25 51 2541 base G front rail pine 25 51 7871 base G back rail pine 25 51 686H 1 top drawer pine/ply 45 254 7872 drawer H sides pine 13 38 2292 drawer H frnts & bcks pine 13 38 7731 drawer H bott plywood 6 254 787J 1 drawer pine/ply 38 254 4642 drawer J sides pine 13 32 2292 drawer J frnts & bcks pine 13 32 4561 drawer J bott plywood 6 254 464K 2 drawers pine/ply 51 254 4644 drawer K sides pine 13 45 2294 drawer K frnts & bcks pine 13 45 4562 drawer K botts plywood 6 254 464L 2 drawers pine/ply 57 254 4644 drawer L sides pine 13 51 2294 drawer L frnts & bcks pine 13 51 4562 drawer L botts plywood 6 254 464M 1 drawer pine/ply 38 254 3182 drawer M sides pine 13 32 2292 drawer M frnts & bcks pine 13 32 3031 drawer M bott plywood 6 254 311N 2 drawers pine/ply 51 254 2984 drawer N sides pine 13 45 2294 drawer N frnts & bcks pine 13 45 3032 drawer N botts plywood 6 254 311P 2 drawers pine/ply 57 254 2984 drawer P sides pine 13 51 2294 drawer P frnts & bcks pine 13 51 3032 drawer P botts plywood 6 254 311materials listI N C H E S M I L L I M E T E R SS T E P - B Y- S T E P construction3736step 8 Assemble the tool chest base G using biscuits. The two frontjoints are mitered, and the back joints are butted.step 7 This is an-other view of the top glue-up. Usingwooden battenshelps distribute theclamping pressureevenly and protectsthe project frombeing dented by the clamps.step 9 Attach the base G to the bottom ofthe cabinet with screws. Use no glue.step 10 Cut out all the drawer parts. Then cut or sand acircular finger pull in the drawer fronts.step 11 Assemble the drawers as shown in project four, steps nine and ten. Re-member to cut the drawer fronts and backs 116" less than the opening that thedrawer will fit into. This will allow plenty of clearance for the drawers to slidefreely. This is not a finely tuned set of drawers. They are made to work smoothlyand still fit nicely in their respective openings.step 12 The drawer bottoms have a 14" lip on each side. Measure the drawer boxes and add 12". Cut thedrawer bottoms to this dimension and center the bottoms on the drawer box. The drawers should fit justright. If the drawers do need fitting, shave a little materialoff the ends of the drawer bottoms. It wont take much,so go easy. If you want to fit the drawers just right, meas-ure the drawer opening from the bottom of each groove,then cut the drawer bottom to this dimension. Assemblethe drawer and try the fit. If the drawer bottom fits intothe grooves (right to the bottom of the groove), you willhave a nicely fitting drawer that will have minimal side-to-side movement.step 13 Assemble the frame and panel door. Then, set the continu-ous hinge into a mortise in the door. This mortise depth should be thesame dimension as the thickness of the hinge so the door will closetightly against the front of the chest.step 14 This is a view of the closed door. (It looks cleaner if thedoor seats tightly to the chest.) You could also set the hinge in astopped mortise if you dont want to see the end of the mortise andthe hinge. Finally, install the door lock.step 5 Using biscuits, attach the ends A to the back/bot-tom assembly.P R O J E C T 5 J I M ' S T O O L B O X ( C O N T I N U E D )step 4 Cut biscuit slots in the ends of the back panel C and match-ing slots in the end panels A.step 6 Cut the necessary biscuit slots in the top edges of the endsand back. Cut matching slots in the top D. (Remember, when cuttingthe slots in the underside of the top, allow for the top overhang at the sides.)3736step 8 Assemble the tool chest base G using biscuits. The two frontjoints are mitered, and the back joints are butted.step 7 This is an-other view of the top glue-up. Usingwooden battenshelps distribute theclamping pressureevenly and protectsthe project frombeing dented by the clamps.step 9 Attach the base G to the bottom ofthe cabinet with screws. Use no glue.step 10 Cut out all the drawer parts. Then cut or sand acircular finger pull in the drawer fronts.step 11 Assemble the drawers as shown in project four, steps nine and ten. Re-member to cut the drawer fronts and backs 116" less than the opening that thedrawer will fit into. This will allow plenty of clearance for the drawers to slidefreely. This is not a finely tuned set of drawers. They are made to work smoothlyand still fit nicely in their respective openings.step 12 The drawer bottoms have a 14" lip on each side. Measure the drawer boxes and add 12". Cut thedrawer bottoms to this dimension and center the bottoms on the drawer box. The drawers should fit justright. If the drawers do need fitting, shave a little materialoff the ends of the drawer bottoms. It wont take much,so go easy. If you want to fit the drawers just right, meas-ure the drawer opening from the bottom of each groove,then cut the drawer bottom to this dimension. Assemblethe drawer and try the fit. If the drawer bottom fits intothe grooves (right to the bottom of the groove), you willhave a nicely fitting drawer that will have minimal side-to-side movement.step 13 Assemble the frame and panel door. Then, set the continu-ous hinge into a mortise in the door. This mortise depth should be thesame dimension as the thickness of the hinge so the door will closetightly against the front of the chest.step 14 This is a view of the closed door. (It looks cleaner if thedoor seats tightly to the chest.) You could also set the hinge in astopped mortise if you dont want to see the end of the mortise andthe hinge. Finally, install the door lock.step 5 Using biscuits, attach the ends A to the back/bot-tom assembly.P R O J E C T 5 J I M ' S T O O L B O X ( C O N T I N U E D )step 4 Cut biscuit slots in the ends of the back panel C and match-ing slots in the end panels A.step 6 Cut the necessary biscuit slots in the top edges of the endsand back. Cut matching slots in the top D. (Remember, when cuttingthe slots in the underside of the top, allow for the top overhang at the sides.)