Step 1: Determine the Size of the Box

The storage case starts out with a simple box. Build the box to the size needed for the chisel collection. Use the longest chisel to determine the length of the box. Leave 1" to 1-1/2" of space between the longest chisel and the edge of the box (for the length). Lay out the chisels side by side, leaving 1" to 1-1/2" of space between them to determine the width of the box. Use the largest chisel to determine the measurements for the sides (depth) of the box (Image 1).

Cut the sides and miter the corners. Attach them to the bottom piece with a brad nailer (Image 2).

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    Image 1

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    Image 2

Step 2: Make the Blade Support

Again, use the chisels to determine the spacing for the blade support panel. Mark the areas that need to be cut out with an 'X'. Then, use a radial arm saw to cut the grooves for the blade support. Make several passes to get rid of all the waste area.

Step 3: Make the Ferrule Support

Create a support (Image 1) for the ferrules on the chisels. To do this, cut holes in a piece of board using a drill press. Use a Forstner bit to drill the holes according to the spacing determined earlier. Then, leave the clearance hole in the drill press open so that you can drill all the way through the board. Using a table saw, cut the board in half (Image 2) so that the holes now become semi-circles. This completes the ferrule support.

Pin the ferrule support and the blade support into place, using a pin nailer.

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    Image 1

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    Image 2

Step 4: Cut and Adhere the Felt

Use adhesive-backed felt inside the box to protect the chisels. Cut the felt to size, then peel off the backing and put in place. Use a dull putty knife to tuck the felt into the crevices of the blade support.

Step 5: Cut the Board

The first step to creating the box lid is to 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.

Step 6: Cut the Plastic

The grooves are 3/16". 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 the plastic slightly smaller than the measurements. If the piece of plastic is too large, the miters will not pull together properly.

Step 7: Score the Plastic

Use a specialty plastic cutter to score the plastic. Make several passes when scoring the material. Use a combination square to ensure a straight line. Then, snap off the excess material.

Step 8: Attach the Hardware

Put the hardware on before putting the frame together. Drill pilot holes for the small brass screws using a bit with a diameter smaller than the screw.

Step 9: Put the Frame Together

It's now time to put the frame together. First, line up the pieces of the frame and use masking tape across the joints. 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.

Attach the lid to the box.