Wednesday 23 November 2016

Fall Front Toolbox (Pt.2)

The toolbox project is making progress.

This is the last week to work on.

By end of the week I will need the completed box

Let us see where I am.

This is part 2 in a loose series of posts about building a fall front toolbox. Find part 1 here.

Front and Back Frame

Last time I was nearly ready with the frame for the front lid. Making a raised panel was the next dance step.

The frame for the front lid

I've prepared two boards and glued them together. This was the base for my raised panel.

Gluing up the panel

Next I've scribed some lines to layout the bevel which had to be established.

Marking the measurements for the bevel

Then I made some shavings. It's the first time I have used a wooden plane for this task. It felt good, because it was not as tiring as using a metal plane.

Planing the bevel

Additionally it has left a nice looking end grain surface.

First bevel done

Finally it looks like this.....

Frame and panel lid

Not bad at all I think.

That done I immediately started with the frame for the back. Good thing - same dimensions for mortises and tenons, so I could transfer the layout. The only thing to change was the length of the styles.
Unlike the front the filling for the back is plywood. I could have done it nicer, but several aspects led into this decision. First of all - time, secondly time, at third position comes weight and finally I believe that the box will be placed somewhere in the shop so that the back won't be seen pretty often.

Both frames ready the main carcass work was done.


I wanted to have two drawers inside of the box. Therefore I've made some housings for the drawer runners.

Housing for the drawer runners

I've renounced to make the drawers yet, because I fear not to get ready. So I will complete the box without the drawers, give it away and getting it back for completion.

Glue up

The glue up was pretty straight forward with no issues. Just gluing up the carcass and the frames.
I have started with the frames.

Gluing up rail and stile

The back frame

Then I have glued up the carcass.

The carcass

And before I could glue on the back frame I have flushed all joints and the rims.

Flushing the joint lines

Having everything flush I have glued on the back frame.

Back frame glued on

Flushing back frame

And that's where I am actually....

Actual state

Target Line

It is Tuesday evening now. The target line is coming closer. I will need this box next Saturday. And I had so many plans.
But a good project manager has always got another plan to somehow fulfill customer needs. I can manage it to get ready with the raw box until Saturday.

What has to be done?
  • Making recesses for the piano hinge into front rail and lid -
  • Planing back frame flush - 
  • Fitting the front rail and gluing on - 
  • Mounting lid to the carcass -
  • Planing lid frame flush - 
  • Mounting handles -
  • Mounting a latch - 
  • Installing a divider for the plane area -  

What's still open then?
  • Making the drawers
  • Finishing the carcass. I wanted to paint it, but now it will be the choice of the future owner.
  • Rehabbing a few tools

What's Next?

I will give away the toolbox on Saturday in this raw conditions. I think it will nevertheless be a nice surprise, because it is totally unexpected.
I'm contrite that it hasn't got the state that I have in mind. I would like to give the box a light vintage used look. I've already aged some of the hardware. Hopefully the future owner will decide to go that way.

Anyway, there will be another post about the box in the near future.

Alright then, this is it for this week. 
BTW have you already seen my first woodworking video? If not check it out here.

Stay tuned!


  1. It's doable but I don't your shop/work/home time ratio. I think on something like this it is easy to obsess about little details that suck up a lot of time. Good luck, I think you will meet your deadline.

    1. Hi Ralph,
      forgotten to write that there won't be shop time Wednesday and Thursday. But I'm on my way and something will be ready on Saturday evening.
      Your are right. A lot of details in mind. Starting by making my own handles and ending by the look of the finishing. That all takes more time than expected.

      Take care,

  2. Replies
    1. Olá António,
      yes. It really is. Getting a bit nervous meanwhile.


  3. "Making a raised panel was the next dance step." - Ha, you sound like Ralph!

    Looking good, Stefan. The raised panel really came out good. You've got a lot of work to do still - good luck finishing on time.

    1. Hello Matt,
      that's learning English phrases by reading :-)
      Sorry Ralph, for borrowing that phrase. But I have read that so often and I like it.
      Thanks for the kind words, Matt.

  4. Replies
    1. Thanks Greg!
      Hope some details will make it look even better.


  5. Stefan,

    The box looks good. I'm with you on using wood stock planes for raising panels, just so much lighter and easier to use.

    Sounds like you understand once you give it to someone they decide, you may not like but at that point it is their box. Whatever it is all good.


    1. Hello Ken,
      thanks. Using the woody was really comfortable. Additionally I recognize that meanwhile I use that wooden jack all the time.
      Yeah, at the end it is like it is. Handed over the piece you have made, it is no longer yours.
      And I'm with you, it is all good.
      If the future owner would like to have it painted, I will do it and if he likes that natural look, then it is fine with me too.