Picture of Cub scout project: Wood Tool Box
  The tool box is one of the projects our cub scout pack builds. Its uses few materials and costs less than $3 per scout.  This is a great beginner project.  The cub scouts learn how to use a hammer, saw, glue gun, and sanding block.
  It takes a little preparation to get things ready for the scouts. The instructable is in two parts, Preparation steps and Scout steps.  Prep steps are done by the leaders prior to the meeting.  The scout steps are done by the kids at the meeting. 
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Step 1: Materials

Picture of Materials
1” x 4” x 8' pine board (Furring strip). One board per two tool boxes. (~$2)
1” x 2” x 8' pine board (Furring strip). One board per 8 tool boxes. (~$1)
1lb box 1-3/8” ring shank drywall nails. One box per 20 tool boxes. (~$4)

Step 2: Preparation step tools

Picture of Preparation step tools
Preparation tools required:
  Miter saw, or hand saw to cut boards
  Tape measure
  Ruler or gauge
  C-clamp (1-1/2” or larger)
  5/64” Drill bit
  Drill press, or hand drill.

Step 3: Prep step 1

Picture of Prep step 1
Measure and mark the boards to be cut.
The 1”x 2” x 8' board should be marked every 12 inches.
The 1”x 4” x 8' board should be marked for six 12 inch pieces, and two 10 - ½ inch pieces.
(The 1”x 4”x 8' board should be marked at 12”, 24”, 36”, 48”, 60”, 72”, 82-1/2” and 93”.)

Cut the boards.

Here's a list of cut parts you'll need for a single tool box:
One 1”x 2”x 12” board. This will be the tool box handle.
Three 1”x 4” x12” boards. These will be the sides of the tool box. (One of these will be cut in half by the cub scout.)
One 1”x 4”x 10-1/2” board. This will be the bottom of the box.

Step 4: Prep step 2

Picture of Prep step 2
On one of the 1”x 4” x12” boards, draw a line across its middle (6” from edge). The scout will cut this board in half. It will be used as the tall sides of the box.

To strengthen the handle, we made it shorter so it fits between the uprights, and is held in place with a screw through each end into the handle from each side. Adding screws to the project let the kids learn to use screw drivers in addition to hammering nails. I pre-drilled holes for the screws and nails, and cut half way through the board, so our second graders were able to cut the rest of the way with a hand saw. Since mostly moms show up to the den, this was appreciated. Thanks for publishing this great project here. It was a life saver.

darman121 year ago
I remember building one of these in Cub Scouts.
unklegwar1 year ago
Oh, also...have them "break" all the long edges with sandpaper, especially the handle, to help prevent splinters.
unklegwar1 year ago
As a woodworker myself, I'm concerned about the use of nails into end-grain for the handle. This is a triple whammy. End grain, nails, soft wood. That connection will eventually fail unless this is just left on a shelf.

I realize this is a kid project, but a handle that easily separates from the box while the child is trying to carry stuff is going to be discouraging. And depending what's in it, might make for a mess or injury.

There's not many easy kid-doable things that can be done to beef up this connection. But even using some glue for the handle will help a little. That joint can use any help available.

I think someone else suggested real wood (PVA) glue, that would help this butt joint, even if not clamped. Titebond I and II will give about 5 minutes of "open" time. Titebond III will give 8. Plenty of time to get positioned and nailed. It's not stringy and cleans up with water. And it's even safer than using a hot glue gun.
nfrith2 years ago
Nice, simple project and perfectly age-appropriate for younger Cub Scouts. I will be doing this with my Wolves on Tuesday night, I will let you know how it goes. One change I made is that I will be using carpenter's glue instead of hot glue, as some others have suggested. Great idea, simple and low-cost - I was able to get my cost under $3 per box.
jacob2die44 years ago
nice work, but yes the glue..
u will bwegreat in time
blkhawk4 years ago
Nice work! Instead of the hot glue melt gun try wood glue or carpenters glue in your next wood projects.
Jayefuu blkhawk4 years ago
Wood glue would be stronger, but hot glue sets faster.... much easier for kids!
3366carlos4 years ago
Very nice, you have goo skills.