Construction Procedures

Skurpski built most of the box from '/»-in. thick exterior-grade lauan mahogany plywood, joining the sized parts together by riveting them to aluminum angle stock (drop-ceiling wall angle). To ease the finishing process, he prefinished the exterior surfaces before assembly. I lealso precut most of the notches in the partitions (to accept certain tools) before installing them to the inside walls and floor (again with rivets to the angle stock). To protect the edges of the lid and to give it some rigidity, he attached a perimeter rim of this same aluminum angle stock.

Making the forked axles

Skurpski made the forks for the bike wheels by bending !/<-in. by 2'/2-in. aluminum bar stock into the appropriate shape; he attached them to the case with carriage bolts running though the fork and into the 1 -in. tube stock fixed to the inside of the box (see the top drawing on the facing page). He attached the casters to the floor of the box, through-bolting into a 3A-in. thick piece of plywood fitted to the inside floor. He also attached the lower lift handle—a piece of '/2-in.

electrical conduit bent to shape with an electrician's brake—to this same backing block. The upper push handle of conduit is bolted to the inside corner of the box through the angle stock.

Making the drawers

To keep things simple, Skurpski used the same method of construction for the three drawers as he employed to build the box, riveting '/-»-in. plywood to an external aluminum-angle framework. To mount the drawers so they would open to either side, he encased them into the corner of the box with two plywood panels, adding horizontal plywood partitions to support the drawers. After rejecting numerous, and invariably complex, solutions to the problem of locking the drawers for transport, he finally settled on a simple stop system (see the bottom drawing at right). A turn of the screw covering the angled slot fixes the lock in cither the closed or open position.

Interior and exterior finish

Though he applied stain and varnish to the exterior of the box to enhance the beauty of the lauan plywood (before assembly, to avoid having to apply the finish around the angle stock), Skurpski realized that such a finish would not work well on the interior. Besides becoming quickly scratched as tools went in and out of the box, the varnished wood would be too dark. Instead, Skurpski painted the entire interior of the box with white semigloss latex enamel paint.

Drawers and Drawer Stop

Drawer stop (one on each side)

Slots angled at 45°

Slots angled at 45°

Aluminum angle

Drawer supports, V-s-in. plywood

Drawers opens to either side of box.

Drawer supports, V-s-in. plywood

Drawers opens to either side of box.

Aluminum angle

Vi-in. by 21/?-in. aluminum bar stock

1-in. square aluminum tubing

Radiator tubing riveted over outside arm of fork covers axle nut.

20-in. bicycle tire

Vi-in. by 21/?-in. aluminum bar stock

Carriage bolts pass through fork, through side wall of box, square

Radiator tubing riveted over outside arm of fork covers axle nut.

Axle

20-in. bicycle tire

Was this article helpful?

0 0
Woodworking Tools and Installation Tips

Woodworking Tools and Installation Tips

There are a lot of things that either needs to be repaired, or put together when youre a homeowner. If youre a new homeowner, and have just gotten out of apartment style living, you might want to take this list with you to the hardware store. From remolding jobs to putting together furniture you can use these 5 power tools to get your stuff together. Dont forget too that youll need a few extra tools for other jobs around the house.

Get My Free Ebook


Post a comment