Finger joints join the four sides. The moulding
is nailed/screwed to the exterior and the lid has
a small piece of moulding attached to it that
acts as a dust seal.
The secret to finger joints is to get all of the
"spaces" and"fingers" to line
up correctly. If one board begins with a space,
then its mate must begin with a finger. The
grooves should be 1" up from the bottom
edge. You may wish to stop these grooves before
you cut into your finger joints and finish the
grooves with a chisel. You can just run these
grooves right through your joints -- since, after
all, they'll be covered by the moulding on the
outside of the case.
the case using glue on the finger joints,
allowing the bottom to float in its groove.
make the moulding by routing a small ogee profile
on the bottom moulding pieces. Miter the pieces,
then attach them with nails or screws.
A dust seal is needed since dust and grime has
never been good for tools. Begin making the seal
by cutting the lid to size and mortising the
hinges into the case and lid.
make the moulding for the back. This moulding is
different because it helps seal the back of the
case and acts as a stop for the lid. It's pretty
ingenious. Take a piece of moulding back to the
table saw and rip off the rabbet.
attach this moulding to the back, flush to the
top edge of the case. You'll have to cut notches
in the moulding for the barrels of the three
hinges that hold the lid. Screw and glue this
moulding to the back. Now cut the cleats for the
sides that hold the rope handles. Use a band saw
to cut them to rough shape and sand them down.
Then drill a 1/2" hole through the center
for the rope. Attach the cleats with screws.
you want to lock to your chest, now is the best
time to add a lock. You can use a small
full-mortise chest lock. Next, add the dividers
for your power tools at the bottom of the case.
Fill all your screw holes with water putty and
finish sand the exterior of the case to 120 grit.
Paint the exterior.
The till is a box that's divided into four
"stories" by wide 3/8"-thick pine
boards that are dadoed into the back and sides.
You access the top level by opening the lid of
the box. The bottom three levels are for nine
bottom sticks out of the case 3/8", which
allows the till to slide on runners in the large
Swage your hinges and then mortise them into the
till and the lid. Then start dividing up the top
tool area for the hand tools that you reach for
you've veneered your case, now is the time to add
a piece of veneer to the front piece and to cover
all the other pine edges that show.
cut your drawers. Fit your drawers into the till.
Finish sand everything and cover the till with
two coats of clear finish. Add a chain to the lid
to prevent it from opening too far.
The till rests on runners screwed into the inside
of the large case. These runners are made by
using your table saw to cut two rabbets in