Dovetailed Tool Box

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PROJECT PLAN #SU7
Dovetailed
Tool Box
Included in the plans: This classic tool case is strong and comfortable to hold, with two removable trays and
plenty of room for hand tools. When you lift out the trays, there is a cavity below that can
n Scale drawings
hold larger tools, such as saws and jointer planes. The box also includes a chisel holder that
n Detailed cutlist can be customized to fit your tools. The sides are dovetailed, and the plywood base fits into
n SketchUp drawing a groove in the sides. The handle is mortised into the sides. Tray construction is similar to
that of the main box.
n Dovetail template
Size: 12 in. deep by 25-1/2 in. wide by 21-1/2 in. tall.
Pp
63 South Main Street
Newtown, CT 06470
(203) 426-8171 To purchase additional plans, visit www.finewoodworking.com/planstore
Taunton Product # 065109
Dovetailed Toolbox
This tool case is strong, comfortable,
with plenty of room for hand tools. The
two trays lift out for access to the open
(non-partitioned) lower section for larger
tools such as saws and jointer planes.
Toolcase, 3/12, Page 1

Exploded view

Cut-away view of lower
compartment

Start with the sides
If you have enough matching lumber,

mark out the ends and sides, and label
them so that the grain is continuous
around the box.
Use the provided full-size template to

mark out the dovetails, and then cut them
with a handsaw.
Note the stopped grooves for the base,

which can be cut with a router. Square off
the ends of these grooves with a chisel.
Use chisels to cut the recesses for the

chisel holder and tray support.

Fabricate the ends, base and part of the inside
Use the side pieces as guides to lay out the dovetail pins on the ends.
Next, cut the grooves for the base and mortise for the handle. The
mortise can be roughed out on the drill press, then squared with a
chisel.
A full-size template is available for marking out the scroll shape.
Drill the shank holes for the screws used to fasten the end to the
buttresses.
Now, cut out the base, which is made of plywood to avoid

expansion/contraction issues. You can use either 1/2-in. or 3/8 in.
material.
Cut out the tray rest and cleat.
Although you have a lot of parts ready at this point, do not be

tempted to glue anything together until other critical parts - base,
handle, and tray support - are fabricated.

Assemble sides, ends, handle, base, and tray support:
Dry fit all parts and prepare for gluing the assembly. Consider using a
slower drying glue such as Titebond III, as it may take more time to
manage the many parts.
Begin the glueup on one set of dovetail joints connecting a side and end.
Add the other side while connecting in the tray support. Connect the other
end while fitting in the handle.
Screw the cleat to the end.

Mill the buttesses
To avoid cross-grain expansion

contraction issues, this piece should
be glued only along the upper 6 in. of
the buttress. Four screws fasten the
buttress to the ends. The shank holes
should be oversized to about 1/4 in.
dia., to allow for movement.
The bottom edge of the buttress

should be 1/8 in. short of the bottom
edge of the end. This gap prevents the
buttress bottom from contacting
surfaces when putting the tool case
down.
Note the chamfers on the buttress

top, sides and bottom end.

Make up the chisel holder
Use your own tools as a guide for the diameter of

the chisel holder holes.
A full-size template is provided to get you started

on the spacing of the holes.
Glue the chisel holder in place; it attaches to the

side cutouts and the end piece.

The trays are next
There are two trays each with dividers to

suit. As an alternative, one tray may be
full-length without dividers.
The trays are dovetailed. Grain direction

of the tray ends is horizontal to match
grain of the sides.
Tray construction is very much like that

for the main box including a captured
base in side and end grooves. The
grooves in the sides are stopped short
and squared off by hand.
Check the actual length dimension for

the dividers after assembly of the tray
sides, ends, and bottom.
-- Tim Killen

Other tray parts:
Before glue-up of sides and ends, have the bottom piece

ready as it is captured in the side and end grooves.
Check actual length dimension for the dividers after

assembly of the tray sides, ends, and bottom.

Side Template Handle
Tray Side
Template
Tool Holder
Box End
Template
Tray End
Template
Toolcase, 02/19/2009, Page 1

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Ski l l L e v e l :

PROJECT PLAN #SU7

Toolcase, 3/12, Page 1

Toolcase, 3/12, Page 2

Toolcase, 3/12, Page 3

If you have enough matching lumber,

Use the provided full-size template to

Note the stopped grooves for the base,

Use chisels to cut the recesses for the

Toolcase, 3/12, Page 4

A full-size template is available for marking out the scroll shape.

Now, cut out the base, which is made of plywood to avoid

Cut out the tray rest and cleat.

Although you have a lot of parts ready at this point, do not be

Toolcase, 3/12, Page 5

Screw the cleat to the end.

Toolcase, 3/12, Page 7

To avoid cross-grain expansion

The bottom edge of the buttress

Note the chamfers on the buttress

Toolcase, 3/12, Page 8

Use your own tools as a guide for the diameter of

A full-size template is provided to get you started

Glue the chisel holder in place; it attaches to the

Toolcase, 3/12, Page 9

There are two trays each with dividers to

The trays are dovetailed. Grain direction

Tray construction is very much like that

Check the actual length dimension for

Toolcase, 3/12, Page 10

Before glue-up of sides and ends, have the bottom piece

Check actual length dimension for the dividers after

Toolcase, 3/12, Page 11

Toolcase, 02/19/2009, Page 1

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