Joiner’s Toolbox

Paul starts this series by going over some of the key aspects of the project, and then goes through the preparation of the stock. This toolbox uses thin stock so we look at the methods used to thickness it by hand.

To prepare for dovetailing the corners, Paul rips a panel to width and shows how to accurately crosscut using a tenon saw. Now we are ready to layout the dovetails and Paul talks through some of the options.

It’s time to start the joinery by dovetailing the four corners of the box. Paul shows a couple of different techniques that can be used and discusses some of the idiosyncrasies involved when there are a large number of dovetails on a corner.

With the four corners dovetailed, it’s time to glue up the main box. Paul introduces a technique he developed to help glue up larger dovetailed boxes where there can be issues due to the fibres swelling once the glue has been applied. Once the glue has been left to set overnight, Paul cleans up the…

This toolbox has a base and top trim that surround the box which helps to solidify the piece and protect the main box from knocks and bumps. Paul goes through the process of cutting the pieces to length then laying out and cutting the dovetailed corners. Accuracy is essential here to ensure they fit flush around the box with no gap.

In this episode Paul refines and assembles the dovetailed base trim. He chamfers the edges and applies the trim to the base of the toolbox using glue and clamps. The trim both decorates and strengthens the base of the toolbox.

Paul moves onto laying out the top trim. He then cuts the dovetails and fits and glues the trim onto the box. With both the trims done, Paul edge joints some stock for the lid of the box using timber dogs. With that set aside, it is time to clean up the trim in preparation for fitting the bottom.

With the trim finished, it is time to fit the bottom of the box. Paul uses ship lapped boards as in the original but diverges slightly. He does this using a rebate plane and then fits them to width so they sit inside the bottom trim. Once these are screwed in place, he fits the bottom cleats which lift the box of the floor and we’re ready to fit the lid.

Paul starts by fitting a hinge bar which support the hinges and helps prevent splitting in the top back edge. The jointed lid stock is cut to size and cleaned up before the lid trim is mitred and attached. This lid trim adds to the integrity of the lid and helps to keep it flat.