- 1). Purchase plywood to cut. For a standard size, the long sides can be 15-by-5 inches, and the short sides can be 10-by-5 inches. That makes the bottom piece 15-by-10 inches. You also need a handle that's 14-by-8 inches with the upper corners cut away for a better shape. Get a 5-by-1.5 inch piece for the top where you will put the handle.
- 2). Use a circular saw to make the main cuts for the toolbox. Clamp the plywood in place as you cut, using a spring clamp on a workbench. Be sure to wear safety goggles.
- 3). Cut the hole in the handle with a jigsaw. Cut starter holes with a 3/8-inch bit and a power drill.
- 4). Sand the plywood pieces you cut out with 120-grit sandpaper and a random-orbit sander for a smooth finish.
- 5). Turn the long sides of the toolbox so that you're looking at the shorter edge. Apply a bead of wood glue and push the short side of the toolbox onto it. Continue until you've made a rectangle.
- 6). Install a 4d finish nail at each corner where the short side meets the long side of the toolbox.
- 7). Apply a bead of wood glue all around the bottom of the connected side pieces. Place the bottom piece over the glue. Hammer in nails at each corner of the bottom piece to ensure that it stays put.
- 8). Put a bead of glue along the side and bottom edge of the handle piece. Place it in the center of the inside of the toolbox. Wait for the glue to dry and then install 4d finish nails through the sides of the toolbox to secure it.
- 9). Apply a small amount of wood putty to conceal all the nails. Once the putty is dry, use sandpaper to even out the surface.
- 10
Add stain to the surface of the toolbox to protect the wood. Use a 2-inch paintbrush and wipe the stain off with a rag after a few seconds.
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