Tony Konovaloff built his box exclusively with hand tools, following the old-fashioned procedure of cutting and fitting one piece at a time. When working with modern power tools, it's generally more efficient to cut out all the pieces at once, but with hand tools, there is no particular advantage to using production-style techniques to prepare or mill the wood. The instructions that follow assume that you will, like Konovaloff, build this box exclusively with hand tools. You may, of course, use power tools wherever you like.
Making up the case After determining the overall size of the box and its interior fittings, sketch out various aspects of the box. When you are happy with the design, you can begin construction. Choose boards for the sides of the box and edge-glue them to width. Hand-plane them flat with a scrub plane and then finish the board's surfaces with a smoothing plane. Next, plow grooves (with a combination plane) near the base of the side and end boards to accept the bottom panel. To bring both visual and physical lightness to the box, you can make this panel up of several edge-joined boards of light-colored alder.
The next step is cutting the through-dovetail corner joints. Cut the tails first, and trace them to mark out the pins. Trim the pins to fit between the tails with rasps followed by files, then dry-fit the sides together around the bottom panel. When you are happy with the tit, reassemble the box, this time using glue in the corner joints and in the middle area of the bottom panel (so it can shrink and expand in its slot from either end). Insert notched cauls under the clamp pads to hold the dovetail joints tight—see the drawing above. Check diagonal measurements to ensure that the chest is absolutely square before setting it aside to dry.
Remove the case clamps once the glue has set and then cut the bottom skirt boards to width and thickness. Cut the end pieces to length and make the pins. Attach these pieces to the box by driving in screws from the interior of the box. Working in this order will help you accurately fay out the tails on the front and back skirt boards and will ensure that these pieces will fit tightly to the case after you cut these joints. Now cut the tails and install the skirts to the case, also screwing them in place from the inside of the box.
Making and installing the drawer tills and other storage fittings
Begin work on the chest interior with the bottom well—a 3-in. high f ramework of dadoed partitions sized to fit precisely within the box. Then make up and insta// the array of hangers designed to hold various tools. Finally, build the four drawer tills, the two open trays and the two removable boxes. Construct these all in similar fashion: hand-dovetailed sides joined around a beveled board inserted into a plowed groove. To support the tills in the case, screw guide rails into the front and back of the case. Note that the top tray on the right is fixed permanently into the box and the top tray on the left is hinged to the
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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.