Of course, building a case for your fine hand tools is more than a practical solution to a storage problem. It's an opportunity to fine-tune and show off your woodworking skills. Our design is based on an early 20th century Arts & Crafts theme and features traditional frame-and-panel construction and hand-dovetailed drawers.
This project was originally published in the January 2001 issue of Popular Mechanics. You can find more great projects at Popular Mechanics DIY Central.
Step 1: Build the case, part 1
Lay out the mortises in the leg blanks so there’s extra waste stock beyond them at the ends. To ensure uniform positioning, clamp the pieces together and use a square to mark across them. Then, lay out the mullion mortises in the rails.
Set up a plunge router with a 1⁄2-in.-dia. spiral up-cutting bit and edge guide, and rout most of the waste from each mortise (Photo 1). Note that the extra length at the ends of each blank supports the router base for these cuts. Then, rout the mortises in the top and bottom rails. After routing, the mortises will have round ends. Square all mortise ends with a sharp chisel (Photo 2).
Readjust the router bit depth and cut the panel grooves in the legs, rails and mullions (Photo 3). Then, lay out and rout the stopped rabbets for the plywood inner sides, and square the rabbet ends.