Improved Wooden Toolbox - A new take on a classic

I wanted to create toolbox that was strong, easy to build, cheap to produce and also had some style. But more than that, I wanted to use recycled materials and for the design to be different enough in a simple and functional way.

I feel like I succeeded.

There are quite a few tool boxes/totes which look similar to mine, but none that have the same versatility. Because of the two extended, parallel handles, I can easily clamp other items/cases to the toolbox--without it tipping to one side--and hold much more in one hand. The metal handles and a vice-grip pliers can also be used in a number of different ways.

The parallel handles also enable tools to be hung between the gap in creates, which allows it to hold more tools with easier access.

The two top cross-braces are spaced far away enough from the handles so a 2x4 or even a 4x4 can be rested on top and used to cut items if no other flat surface is available. The braces are skinny enough to be used for clamping. And if repeated clamping and cutting damage or dent the braces, they're the only pieces which use screws to hold in place and are easily replaceable if needed.

Most everything (except the previously mentioned four screws and polyurethane) was made using salvaged materials, making this project environmentally friendly and very cheap.

It's strong and probably took me two hours to build, over the course of two days.

Step 1: Tool and Materials

Although I used a bunch of different tools, this toolbox could be made using only a jig saw and drill.

The material list is adaptable as well. I used 3/4'' plywood scraps because it fulfilled my design needs and that's what was available at the time. 1x6 pallet planks were my original wood of choice when I first envisioned this project.

The handle was made out of old, rusty rebar. I thought about using electrical conduit, but I liked the strong thinness and industrial/construction look of the rebar too much to change. The fact that the rebar was laying in the yard for the last ten years and was never going to be used was an added bonus. Wooden dowels, PVC piping or even threaded rods could be used as suitable alternatives.

Power tools I used:
Table saw
Miter saw
Router
Angle grinder
-wire wheel
-metal cutting disc
Drill
-thin bit for pilot holes
-paddle bit for handle holes

Materials I used:
plywood scraps
rebar
old nails
screws
polyurethane

Also used:
Table measure
Pencil
Goggles (for cutting)
Work gloves (for rebar work)

Comments

[pfred2]

Looks like a fine tool tote to me. Good job!

[bpoundah]

Thanks. I've never put so much thought into design before.

[pfred2]

It is amazing what we are capable of if we allow ourselves to do them. One of my favorite sayings is the only limits are the ones we place upon ourselves. I am working on a challenging project right now and I just got what I think is yet another brilliant idea for it myself as I drifted off to sleep last night. Now I'm happy I procrastinated and didn't do what I was going to do originally. So what I'm trying to say is it pays to put in that thinking time. After everything is all done the only thing that matters is the end results. Not how long it took you, or how much work you did etc. All of that is in the past and you are left with what you have. I'd rather do a few great things than a bunch of so so things. As others wiser than me have said, anything worth doing is worth doing right.

So keep on thinking, designing, then choosing the best you can!

[r_harris2]

Good recycling! If the rebar gets to be too much for your hands (which may depend partly on the state of calluses and partly on how often you wear gloves), you might try a string wrap to soften the grip.

[bpoundah]

That's a good idea. The rebar isn't too tough after cleaning it with the wire brush but the skin on my hands are pretty baseball glove-like :P