I made it at Techshop: http:www.techshop.ws
Step 1: Materials and Equipment
1/8 plywood or MDF (about 12x12 inches) for tool bit trays
screws and/or CA glue for hinges and latch
finish ( I used water based polyurethane)
paint for lettering (I used some nail polish)
Step 2: Design
The bit trays are removable, so I can set them on the work bench when I am working. The trays have to be held in place in the box with the tips of the bits near the lid. This will prevent the bits from spilling all over the inside of the box during storage and transport.
I decided to use some existing plastic snap boxes for the disks and drums.
Appearance wise, I was going for a retro-ish machinist tool bit storage look.
I designed some plastic hinges and latch hardware for the 3D printer, but decided to go with metal hinged. I kept the latch.
The box design was made using a web based boxmaker that pumps out a PDF file. It is important to know the exact thickness of your plywood (not the same as the nominal thickness) and the kerf size when cutting this material on your laser . So it is best to select your wood and do some sample cutting with your laser BEFORE drawing the box. I imported the PDF into Corel Draw, and modified to add lettering, and a flush lid that wood accept hinges and a latch.
I designed some bit holder trays that would fit inside the box, but could also be used stand-alone. Te trays are angled slightly to make it easier to access the bits.
I have included my cut files for your reference, but you will need to adjust (or redraw) for your specific wood and laser.
If there is interest, I can post the instructions and files for the3D printable hinges and latch.
Step 3: Cut and Assemble
Using the settings from the test runs, raster out the lettering and cut out the parts on the laser.
After cutting, paint in the lettering. After the paint dries, remove the tape.
If you made the fit tight, the box and trays can be glued without clamping. Ensure the the sides are square, and that the lid has clearance.
After gluing, apply final coats of varnish
I used MDF core plywood for the box, which is not so great for holding screws, so I simply glued the hardware in place with CA glue. It looks to have held quite fast.
Step 4: Test Drive