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Toolbox


Materials:
  1. 1 @ 1" x 8" x ~20 (for the ends)
  2. 1 @ 1" x 8" x 22.5" pine (for the bottom)
  3. 2 @ 1" x 3" x 22.5" pine (for sides)
  4. 1 @ 24" diameter wood dowel
  5. About 10 wood screws
Tools:
  1. jigsaw and crosscut saw
  2. drill with 3/32 bit and countersink
  3. 1 1/8" Forstner bit
  4. impact driver with Philips head bit
  5. sand paper
Steps
  1. Get 2 pieces of 1x8 and 2 pieces of 1x3 from me.
  2. On the short piece of 1x8 mark the "ends" piece in half, both lengthwise and cross-wise.
  3. Mark the end pieces using the template.  (end of day 1)
  4. Cut the rounded part of the ends with jig saw, then use the template and router with flush-cut bit to trip to size. (day 2)
  5. Mark each end piece where the 7 screw holes and one dowel pocket will be (day 2)
  6. Get approval, then drill and countersink. (day 3)
  7. Get someone to help you screw one end to the sides, careful not to strip the driver slot.  (day 3)
  8. Place handle and end into place then repeat step 8 for second end.  (day 3)
  9. Hand-sand curves and edges, then RO sand the flat surfaces (day 4)
  10. Prime, paint, and/or seal as desired. (at home)
Timeline
Day 1:  
1. Draw 2 lines on each side of your "end" piece, bisecting it in both directions.  
2. Use the template to trace the outline of the two ends.  
3. Cut outside the line with jigsaw

Day 2: 
1. Clamp one end to the template and I'll trim it using the trim-bit in the router
2. Sand the inside of your 2 ends and 2 sides
3. Mark where the pilot/countersink holes will be and drill them

Day 3:
1. Mark where the dowel will go into the end (at center) and bore with 1 1/8 Forstner bit
2. Round-over the inside and outside of the top of the side pieces.
3. Cut a dowel to be the length of the bottom plus 7/8".

Day 4
1. Assemble box (bottom to end, sides to same end, then insert dowel and repeat for other end)
2. Round-over the bottom and sand the sides and ends
3. DONE!

Chris' Notes to Self:

For 24 boxes you need to buy:
    1. 12 @ 1x4x8' (each piece becomes 4 sides)
    2. 12 @ 1x8x8' (12 x $12.75 = $153) (each piece becomes 2 bottoms and 2 double-ends) 
      OR  6 @ 1x8x8' (cut to 24@23" for bottoms) and 4 @ 1x8x10' (cut to 24@20" for ends)
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