Reply Upvote. Glue, then nail the other tall side to the bottom. Need Help? Eagle Scout. Court of Honor Banquet Supplies Gifts. Home Cbu Wood Kits.

I cut one 1" x 6" x 15" board in half length wise to make two 1" x 3" x 15" boards to be used as the sides. Originally I planned on cutting the tapers for the end pieces on my tablesaw and drawing the cut line in the middle of the board and letting the scouts make that cut with their handsaws.

After testing the hand saw out on a piece of scrap wood, I wisely opted to switch the cuts and use the tablesaw to cut the ends to size. I also cut most of the way through the taper cuts with the tablesaw in order to make it quicker and easier for the scouts to finish the cuts with the handsaw. Even with most of the material removed by the tablesaw in the taper cuts I was a bit worried about how the final cut would look because when I tested the handsaw I used it as I would normally use a handsaw and the cut was fairly ragged with the teeth of the saw tearing small chunks out of the backside of the wood instead of cutting cleany through the wood what do you expect for a dollar lol.

Fortunately the scouts did not apply as much pressure to the handsaw when they used it as I did during my test cuts. So even though their cuts took a little longer to make, they looked much cleaner than my test cut. Obviously, dollar store tools will not become family heirloom tools; but the scouts were thrilled with the concept that they got to keep the tools that they used to build their toolboxes.

I also added a second screw at the bottom of the end. Looking back on the project, it would have been much easier if I had made a few drilling jigs to get repeatable results on the pilot holes that I drilled for the assembly process.

Instead I opted for the much more difficult and time consuming process of drilling all the pilot holes by hand and marking each join with hashmarks look closely in the pictures of this step and you will see them so that the parts could be put together again by the scouts and all the holes would line up properly.

Once I was satisfied with the assembly I just had to put the drill in reverse and remove all the screws and pack up each kit individually.

We did not have time to paint the toolboxes that night, but several of the scouts did say they were going to paint their toolboxes.

If they send me pictures of their painted toolboxes I will add photos to this step. Question 1 year ago on Step 6. Answer 1 year ago. More by the author:. Camp Comfort. Chairs Hammocks Lifetime Furniture. Flashlights Lanterns Accessories Headlamps. Cameras Power Communication Batteries Entertainment. Camp Kitchen. Pinewood Derby. Raingutter Regatta. Space Derby. Eagle Scout. Court of Honor Banquet Supplies Gifts. Party Supplies. Other Events.

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