Step 2: Cutting

What you want are:

(3) pieces of wood that are the same width
- (2) of those pieces should be the same length (ends)
- (1) will be the box bottom

(4) pieces of wood that are length of your box bottom PLUS the twice the thickness of the end material
- (2) should be thin
- (2) should be wider

How long and how wide you want these pieces to be will depend on your needs and materials.

As for my box, the measurements are, in inches:

Bottom (1) - 8 W x 13 L

Ends (2) - 8 W x 12 L

Sides, upper (2) - 1 W x 14.5 L
Sides, lower (2) - 3.5 W x 14.5 L

The dimensions of the sides can be played around with the most to reduce waste. Having two rails for the sides isn't even completely necessary, it just makes clamping possible and reduces weight slightly. Cutting the corners off the ends isn't necessary either, as it's mostly done for aesthetic purposes. I cut the corners because...well, that's how toolboxes look like. It's a classic shape that's easily recognizable and has stood the test of time. I feel it's what separates a toolbox from a box with tools.

With that said, the corners can be cut almost any measurement. I used the golden ratio as much as possible. Mathematicians/artists/architects have been obsessed with this ratio for thousands of years and say it's more aesthetically pleasing, so why not use it for an otherwise arbitrary cut.

If you decide to cut the corners using that method this website is very helpful. My golden ratio measurements are on one of the pictures.

The handle should be a few inches longer that the total length of the box (the length of the sides). I cut my rebar pieces to 16.75" to give me about 2" of overhang, which is all I needed to clamp my drill case, but I'd suggest anything from 3"-6" would be good. You should follow your needs.
<p>Nice Tool Box. The design is excellent!!</p>
Looks like a fine tool tote to me. Good job!
Thanks. I've never put so much thought into design before.
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. <br> <br>So keep on thinking, designing, then choosing the best you can!
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.
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

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