Step 5: Prep Step 3

Mark pilot holes.
  Pilot holes are helpful for younger scouts who are making the tool box. Pre-drilled pilot holes will help the nails start straight and keep them going true.
  All pilot holes are 3/8” in from the edge of the boards. Since the thickness of the boards being nailed is 3/4”, placing the pilot holes 3/8” from the edge will keep the nails in the center of those boards. If you have a gauge or caliper lock it at 3/8”. Place it against the edge of the board, then make a pencil mark at its end. This will give you consistent edge placement of the holes.

Pilot hole locations:
  Handle 1”x2”x12”: On both ends, in middle of handle. (3/4” x 3/8” from corner)
  Long sides 1”x4”x12”: On both ends in middle (1-3/4” x 3/8” from corner)
  Two in line along the bottom of the board (4” x 3/8” from opposite corners)
  Tall sides 1”x 4”x 12”: Two in line along the left of the board ( 1” x 3/8” from corners)
  Two in line along the right of the board (1” x 3/8” from the corners)
  Bottom 1”x 4” x 10-1/2”: No holes.
<p>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.</p>
I remember building one of these in Cub Scouts.
Oh, also...have them &quot;break&quot; all the long edges with sandpaper, especially the handle, to help prevent splinters.
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. <br> <br> 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. <br> <br>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. <br> <br>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 &quot;open&quot; 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.
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.
nice work, but yes the glue.. <br>u will bwegreat in time
Nice work! Instead of the hot glue melt gun try wood glue or carpenters glue in your next wood projects.
Wood glue would be stronger, but hot glue sets faster.... much easier for kids!
Very nice, you have goo skills.

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