This is my first Instructable so please bear with me.
At our house we're in the process of cleaning closets and cupboards. We live in a small apartment, having moved here from a four bedroom 3000 square foot shingle style colonial home three years ago. Organizing is very important as space is at a premium. When I needed some containers for organizing my toolbox, I looked around and found an excess of cardboard, some duct tape and wooden dowels... Seeing the little metal apprentice toolboxes in this Instructable-
reminded me of making that project in metal shop more than 25 years ago. Ultimately the cardboard proved a bit heavy for scoring and bending, but I made two 11" x 7" and six 2" x 4". All eight pieces sat flat and were relatively square for a project built with trembling hands a couple of the handles are a bit wonky, when I drilled through the duct tape the adhesive got a bit gooey and hung up, causing the tab to deform... Anyhow, let's build.
Step 1: A Pattern Makes Everything Go Better.
I always draw patterns on quarter inch graph paper, even if drawing freehand with no particular scale in mind. My cheap HP Multifunction printer has an unexpectedly fine scaling so sometimes I get lucky and only do one draft of a pattern. Please disregard the numbers on this pattern, and count quarter inch squares, you'll come out just fine.
Remember to measure accurately and pay careful attention to the notches between the tabs and the sides, with out the notch and simply cutting one scissor cut will not allow enough room to compensate for the thickness of the material and it will not fold properly.
When your pattern is drawn, check your lines again with a ruler. If everything is uniform cutout your pattern and go on to the next step.
Step 2: Trace Accurately
A couple of small binder clips to hold your work in place make keeping an oddly shaped pattern in place much easier. I also like to run at least one straight line of the pattern along a straight edge of the material, that and working from left to right from the edges are secrets that simplify this process. I like a black gel rollerball pen, most people do not. I would suggest a black felt tip fine point pen, but a round tip permanent marker is fine, beware the chisel point along contours and corners.
Once you've traced the pattern onto the material, remove it and set it aside. I always save my patterns either scanned or in a banker's envelope.
Using kitchen shears cut your box blank.
Step 3: Score to Make Straight Bends
Once you've finished cutting your blank use a ruler and your pen to mark the scoring lines by drawing lines connecting the inside corners of the notches. Score the cardboard with a scoring wheel, a table knife or like me, a plastic pizza cutter that I received free for buying a hear shaped pizza for my Sweetie, don't cut through the cardboard, just make a clearly visible indentation. After scoring, pre-fold the blank to make gluing and clamping easier
Step 4: Gluing and Clamping
You'll need glue, a cotton swab (a few if making more than one box) and some spring type clothes pins. Remove any poly tape from gluing surfaces. Apply a thin layer of ordinary white glue to the tabs, spread evenly.
Step 5: Fold and Clamp
Carefully fold in the end tabs and press them against the sides. This part is always a bit awkward for anyone with only one thumb on each hand... Clamp in place with a clothes pin or whatever you're using. Let dry for at least 8 hours.
Step 6: Covering and Installing the Handle
When the glue is dry remove the clamps and cover your toolbox in duct tape or contact paper. It isn't a mandatory thing, but will add greatly to the structural integrity of the box. When its covered cut a 1/2" dowel to the appropriate length and drill a hole in the center of each end. Measure a 1/4" down from the point on each end and then drill those holes. Remember snug but not tight enough to punch a hole in the dct taped cardboarduse small woodscrews to attach the handle.
I hope you've enjoyed my first instructable. I enjoyed writing it.