It was my Cousin's birthday this past week and I decided to make a toolbox for him with the help of my Dad. It took two days to make the toolbox. The toolbox was made out of solid Oak wood and I was able to use many tools and woodworking skills. The handle was made out of something special! Below I have written out the steps and included some pictures and some videos that explain how we made it!
We designed our tool box to hold real tools, but could also be used for other things like toys. Our first step was to make a plan:
Using our plan, my Dad cut out all the pieces using the Table Saw and Miter Saw. I was able to help him, but I am not allowed to use these power tools. So I took a picture instead.
I then marked out all the pieces. All I needed for this was a ruler and pencil.
Next was to cut angles on the end pieces. For this, you can use a Hand Saw or a Jigsaw. I tried both and prefer using the Jigsaw because it is easier to push through the wood.
Then, I sanded the edges smooth.
The bottom piece was not flat so my Dad used a Hand Plane to flatten it. I took a slow motion video:
Then, I sanded all the pieces smooth.
After sanding we used a Router to round all the edges of each piece.
Now it is time to explain how we made the special handle. We made it out of our old Christmas Tree!
We used a Draw Knife to get all the outer bark off. Once all the outside wood was off, we did the same thing for the inside bark. Our hands were really sappy. Here is a video of me using the Draw Knife:
After getting all the bark off, my Dad showed me how to use a Tenon Cutter. A Tenon Cutter makes the Diameter of both ends equal (Diameter means the size of the circle). This is an important step because the handle sits in the end pieces.
We then drilled the holes in the end pieces to match the diameter of the handle. To show how the handle fits and how the toolbox goes together here is a video:
We made some final sanding touch-ups and then glued and drilled it together!
Last step was to add some natural oil to protect the wood.
And drop it off at my Cousin's house for his Birthday Present!
















