How to Build a Mechanics Toolbox

Box

• 1

  Measure and cut three pieces of three-quarter-inch plywood, each 24 inches by 18 inches, followed by two pieces that are 19 1/2 inches by 18 inches; these will form the base and sides of the toolbox.

• 2

  Lay one of the 24-inch-by-18-inch pieces flat to form the base, and hold another piece vertically, against the edge of the flat piece, to form one wall. Drill quarter-inch holes through the wall where it meets the base, drilling into the wood of the base, then secure the two pieces together with 1 1/2-inch screws, so you have an "L" shape.

• 3

  Repeat on the other side to put the second wall in place.

• 4

  Put one of the 19 1/2-inch-by-18-inch pieces in place at one end. Drill holes every three inches around the edges, then screw in place, the screws going through into the ends of the walls and the base. Repeat at the other end to complete the basic box.

• 5

  Cut four 10-inch lengths of quarter-round dowel. Glue one vertically in each corner of the toolbox; the tray will rest on these.

Tray

• 6

  Cut a 23 3/4-inch-by-17 3/4-inch section of the three-quarter-inch plywood to make the base of the tray in the toolbox.

• 7

  Cut two 23 3/4-inch lengths of 1-inch by 4-inch lumber, followed by two 16 3/4-inch lengths of the lumber; these will form the walls of the tray.

• 8

  Place the cut lengths of lumber together to form a rectangle, with the shorter pieces between the ends of the longer pieces. Screw the pieces together, using 1 1/2-inch screws.

• 9

  Lay the 23 3/4-inch-by-17 3/4-inch piece of plywood on the rectangle, squaring it against the sides. Drill holes every three inches around the perimeter and secure in place with 1 1/2-inch screws.

Handle

• 10

  Cut a 22 3/4-inch length of 1-inch-by-1-inch lumber; this will be the tray handle.

• 11

  Turn the completed tray over. Measure and mark the center point along both the shorter sides of the tray.

• 12

  Slide the handle into the top of the tray, adjusting so that the marks line up with the middle of the handle. Screw in place.

• 13

  Place the tray in the toolbox.

Completing the Toolbox

• 14

  Measure the outside dimensions of the toolbox, and cut a piece of three-quarter-inch plywood to size to make the lid.

• 15

  Screw three sets of hinges along one of the long sides of the lid.

• 16

  Place the lid on the toolbox, and screw the hinges to the side of the box.

• 17

  Attach a hasp for the padlock to the other long side of the toolbox.

• 18

  Place the handle in the center of the lid and screw in place.