Cutting list…

Welcome! Forums Project Series Tool Chest Cutting list…


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  • #13922
    Joseph Sellers

    I know many of you are eager to start the tool chest build. A few of you have asked for a cutting list (@robinhc, @avillalo, and others?).

    This list comes with a warning. If you are going to prepare your wood ahead of the videos please make sure you have extra wood. I cannot anticipate or fully explain how the wood will be configured or exactly how to prepare it without you seeing the videos. I think this will be enough for you to get an idea of how much rough stock to get. I suggest waiting on the final prep until you see the videos.

    We are using mahogany in the videos but pine will work great.

    Here goes.

    Main box:
    Front: [email protected] 3/4″ x 5 7/8″ x 24″
    Back: [email protected] 3/4″ x 11 3/4″ x 24″
    Sides: 2 @ 3/4″ x 11 3/4″ x 18″
    Rail: [email protected] 3/4″ x 1 1/2″ x 24″

    Lid and bottom frames:
    Long rail 4 @ 3/4″ x 3″ x 26″ (allows 1″ extra length)
    Short rail 5 @ 3/4″ x 3″ x 16″

    Important note:
    Panel material will be sized to finished frames after joinery is completed as there may be some variation depending on individual sizing by participants. Suggest participants add 1/2″ or so to be safe and then cut and fit to exact size later.

    Plywood panel for bottom frame:
    Ply for panel: 1/4″ x 13 3/4″ x 19 3/4″
    Solid panels for top frame
    Panels: 5/8″ x 8 3/4″ x 13 3/4″

    Plywood compartment bottom: 3/8″ x 17″ x 22 3/4″ (must be cut and planed tight)
    Panel support: 7′ lin feet @ 1/2″ x 1/2″
    Internal trim: 7′ lin feet @ 1/2″ x 1/2″ quadrant or triangle

    We have not yet filmed the sections for draw making but here are some estimates:

    1 @ 3/4″ 3″ x 23″
    1 @ 3/4″ x 2 1/4″ x 23″
    2 @ 1/2″ x 3″ x 17 1/4″
    2 @ 1/2″ x 2 1/4″ x 17 1/4″
    1 @ 1/2″ x 3″ x 23″
    2 @ 1/2″ x 2 1/4″ x 23″


    Thanks Joseph, nice job


    Thanks Joseph for posting this here. A few questions:

    The use of plywood makes the bottom frame stiffer since you can glue it into the frame? I was not expecting ply for some reason.

    Are drawer components usually made from hardwood to resist wear?

    Looks like the cut list may be missing the drawer bottoms…

    -Scott Los Angeles

    Brian Loran

    Will the videos go into the drop front tool box as well? If not, could we still get a cut list for it as well? I know the techniques and size will be similar but it helps me make sure I buy enough lumber for both in one run.


    Will the videos go into the drop front tool box as well?

    I hope so. I kind of like the drop front version.

    Robin ... Richmond, Virginia, USA



    Are there any suggestions for hardware? Based on the weight of the lid, I would guess that more than two hinges are needed.

    Also, any suggestions on lid stays? Because of the “depth” of the lid, it appears that some of the more common stays won’t work. Is a chain the best solution?

    Paul Sellers

    Two hinges is plenty if they are good quality brass hinges. I have done it with both two and three hinges, depends on my mood. One thing I should warn everyone of is that you should get some kind of stay or chain on. If the lid accidentally falls back it will break somewhere around the hinges. I use brass chain. It’s the very best for this situation.
    Re the fall front tool box. I think by the time we have finished this box everyone will have had enough. I may do a blog on the other but that’s only if time permits. The fall front is so very similar to the top lid that anyone completing the tool chest will readily be able to adapt to the fall front.


    How big should the hinges be? 1″ hinges big enough, our do they need to be bigger.


    Hey Dan I’m going with 2″ hinges


    Thanks Ken! I’ll keep an eye for some that size next time I’m out at a hardware store.


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