DIY Network

Shop Storage Solutions: Chisel Storage Box - Part Two From "DIY Tools & Techniques" episode DIT-305

This storage box will safely and conveniently store your chisels.

David Thiel finishes the chisel box by adding a framed plastic lid.

The frame for the box lid is four-sided, with mitered corners. A clear piece of thick plastic is inserted in a groove inside the frame.

(Instructions for finishing this project are continued below.)

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	Figure A
	Figure B
	Figure C
	Figure D

• First, cut the 3/16" groove. Use one long board, then cut it down to size later. Be sure to work with the boards flat on the table saw.

• Reset the saw to cut the board the height and width of the frame. Move the fence over, then bring the blade up so that it just clears the material - a tooth above is a good height reference.

• The grooves are 3/16" (figure A). Figure the measurements for the piece of plastic by taking the size of the opening in the box and adding 3/8" to account for the grooves. Cut your plastic slightly smaller than your measurements. If the piece of plastic is too large, the miters will not pull together properly.

• Use a specialty plastic cutter to score the plastic (figure B). You will need to make several passes when scoring the material. Use a combination square to insure a straight line. Then, snap off the excess material.

• Put the hardware on (figure C) before putting the frame together. Drill pilot holes for the small brass screws using a bit with a diameter smaller then the screw.

• It's now time to put the frame together. First, line up the pieces of the frame and use masking tape across the joints (figure D). Then, glue the pieces together and fold the frame around the joints. The tape will bend around the corners and hold the miter tightly together while the glue dries. Tape the last corner or use pin nails to hold the frame together.

• Finally, attach the lid to the box.

RESOURCES :

Noden Adjust-a-Bench
Geoffrey Noden Furniture Design
Website: www.adjustabench.com

Table Saw and Drill
Hitachi
Website: www.hitachi.us.com