DIY Tool Cases

Cutting Out Parts

• 1

  Lay the tool or small group of tools on a piece of 1 to 3 inch thick foam, depending on how thick the tools are. Make the foam about the same thickness as the tool. Use a straight edge to draw a rectangle around the tools.

• 2

  Cut the rectangle out with a utility knife. Trace around each tool and cut it out. Trace around the outside of the foam you cut out and make two more rectangles the same size.

• 3

  Cut two pieces of 3/4-inch thick plywood the same size as your foam, using a table saw. Cut two pieces as wide as the height of all three thicknesses of the foam you used, plus 1 1/2 inches and as long as the short edges of the rectangle. Cut two the same width 1 1/2 inches longer than the long edge of the rectangle. Use the table saw to cut the pieces to width and the miter saw to cut them to length.

Building the Case

• 4

  Apply glue to the short ends of the end pieces you cut. Nail one of these pieces to each end of one of the long side pieces you cut, driving the nails through the long piece into the ends of the short pieces. Use a pin nail gun and four 1 1/2 inch nails in each corner. Nail the remaining long piece to the opposite ends of the short pieces.

• 5

  Apply glue around the edges of the two large plywood panels. Fit these panels into the rectangle frame you built so that the outside faces of the panels are flush with the edges of the frame. Nail through the rectangle frame into the edges of the plywood panels, with one nail every 3 inches.

• 6

  Set your table saw blade to maximum depth. Adjust the fence so that the blade is centered in the width of your rectangle case frame. Start the saw and run one long edge of the case over the blade to cut it in half. Space two utility hinges 2 inches in from the corners. Attach the hinges to the box so that they bridge the cut. Use one 1/2-inch screw through each hole in each hinge.

Finishing the Case

• 7

  Start the saw and cut the remaining three sides of the case. Attach a hasp to the edge of the case opposite the hinges, bridging the cut. Use 1/2-inch screws as before to attach it.

• 8

  Position a 3-inch utility handle centered on one half of the long edge opposite the hinges above the hasp. Use 1/2-inch screws to attach it.

• 9

  Fit the foam pieces into the case with the cut out piece in the center. Set the tools into the foam outlines.