Locate point B '/¡H higher than point A and Vt W to the side, as shown. The length of the swing arm (L) between the pivot points can be calculated using the Pythagorean theorem:
When the points are correctly located, the tray will just clear the corner of the box if it is held level as it pivots open.
Constructing the swing-out trays Cut the parts to size, using gang-cutting methods on the dividers to ensure uniformity. Dado the sides and ends for the bottom panel and dividers, then glue and nail the parts together. If you leave some dividers loose, you can change the arrangement of compartments later. Rabbet and install the tool holder, if you want one in your box. You can use the assembled lower box as a jig to hold the tray assemblies square while they dry.
Rather than trying to shape the handle arms from 1 '/s-in. thick stock, it is easier to cut the notch for the stop dowel in a separate piece of wood and then laminate it to the longer section (see the top drawing on the facing page). Law used 3/<-in. stock for the notched piece.
planing it down to 3/s in. after the pieces were joined. Cut the counterbore for the pole at the top end of the arm (it need only be about'/»in. deep), and cut the slotted hole for the through bolt toward the bottom of the arm. You need to step-cut the slot as shown, to fit it around the nut holding the bolt to the box.
Making the swing-arm fittings Cut the four swing arms to length (at least Vi in. longer than the distance between the two pivot points, as shown in the bottom drawing on the facing page) from a '/s-in. by '/s-in. aluminum bar. In each arm. drill a %4-in. hole for a #6x'/2-in. round-head wood screw at one end and then drill and file a '/«-in. wide by '/»-in. long slot for the pivot bolt at the other. Now cut the V*-\r\. steel rods to length (be sure to allow enough length to accommodate lock nuts over the arms at either end), and thread the ends to receive the V+-20 lock nuts. File the threaded ends of the rods passing through the base of the box until they fit snugly into the slots you cut in the arms. File the flats at either end of the rod parallel to one another so that the arms w ill also sit parallel to each other once installed. To be sure that the flats are parallel, final-fit the arms to the rod with the assembly laid across a large flat surface.
Final assembly s jde the pivot rods into the lower box and install the arms at either end. Set the swing-out trays on the box and attach the swing arm to the trays at each point B using a #6x'/2-in. round-head wood screw through each %4-in. hole in the swing arms. Use a flat washer between the swing arm and the tray. Test the operation—the inside corner of the tray should just brush the outside corner of the box as the tray swings down to the side. You can plane a light roundover into the corners to prevent binding. Set the handle arms in place over the •ot bolts, fixing them loosely in place th lock nuts. Then insert the pole into recess cut for it at the top ends of the handle arms, securing it with screws. Test the operation of the swing handle as you tighten down the lock nuts: It should easily swing down to one side (the side opposite the pine tool holder, to avoid catching on any tool handles), and pull up to engage the stop dowel. If the upper arm catches on the swing-arm lock nuts, file them down until it clears.
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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.