instructables

3-Tier Toolbox

by wafflebeaver

The rst time I saw a sewing box I was ~ 8 years old at my grandmother's house who used to be a dress-maker. She
used to use this sewing box to organize her thread, some small fabrics, needles, scissors, and etc.It wasn’t until after
college while probably helping her change out some plumbing xtures that I found the sewing box again and re-
discovered the ingenuity of these fold out storage containers. Her box was actually more complex than the one I’m
making. It’s actually 5 boxes, 4 are the same size and the bottom one is the base for the other boxes. All made out of
wood and the damage from decades of use has made it seem like it’s had added character. So maybe this idea really
started decades ago.

I wanted something small, portable, and novel and started designing this idea while reading my grandmothers
book about plantation clothing in Hawaii. I su ered from feature poisoning where too much features can poison
the whole project. The latch really gave me trouble. I redesigned the back plate more than 4 times. I was just
making this thing way more complex than I needed to.

When I saw this contest closing, I just thought I had to nish this, thing get it over with and start using it. In the
end, it's not too bad. I don't love everything about it but it'll be functional and my tools will t in my car a lot easier.
Most of all, I think I can show this to my grandmother one day soon and let her know that she in uenced me.

Supplies:

1. 3 boxes the same size in height, width, and depth

2. Backplate - I made mine out of 3/4" baltic birch plywood scraps
3. Hinge arms top and bottom - total quantity of 4 made out of 1/2" baltic birch plywood scrap
4. Hinge arms middle - total quantity of 2 made out of 1/2" baltic birch plywood scrap
5. 3/4" foam sheet from shipping waste for the bottom of the top and middle boxes
6. 1 1/4" woodscrews
7. 5/8" woodscrews for the handles
8. Nylon strap I got from old ratchet straps

3-Tier Toolbox: Page 1

Step 1: Design

Start by drawing the most simplest version of the sewing box version I wanted. My rst iteration was
simply 3 boxes with the arms so I could learn how the arms work relative to each other.
My third iteration was pretty much the basis of what I wanted, but I decreased the material in the
back plate a little for the nal iteration.
The nal was where I really thought more about the function and how these boxes would work.From
the nal iteration, I would generate a parts list of pieces I would need to buy or fabricate. Something
not listed in here is brass grommets and some old damaged surfboard straps that I used for the
handles.
The second iteration created was a little to fancy. Also, I looked at the scraps that I had available and
changed my design to use less material.

3-Tier Toolbox: Page 2

This was done all on Sketchup. Autocad, fusion, solidworks, bluebeam, paper & pencil etc. would all be ne. Main
thing is take some time to make some iterations. I nd that my imagination and problem solving starts to work
better when I really think about my design and how I can build this object

Step 2: Make a Box, Then Make Two More

I make random boxes all the time so I had these three
lying around. Another option would be to buy some
cheap pre-made boxes on amazon or from IKEA.
I added 3/4" packaging foam I received from buying
an expensive piece of equipment online to attach to
the bottoms of the top and middle box. Using
something that can compress is helpful when closing
the boxes.
The bottom box just need Feet. I used 3/4" plywood.
You can get away with using just two feet but it was
just a little easier to work with assembly installing 4
feet and it just feels more stable.

3-Tier Toolbox: Page 3

Step 3: Fabricate the Hinge Arms

These hinge arms are made out of 1/2" plywood. I rounded o the corners with a router and template. You can also
use sandpaper and a sanding block if not available.

Important: Make sure the spacing of the holes relative to each other on each arm are the same. Also drill the holes
so they're just a 1/32" larger in diameter than the screw thread you're using. This is what will make the hinge
mechanism work.

3-Tier Toolbox: Page 4

Step 4: Layout Holes on Boxes

Layout the Hinge arms with the three boxes. Take your hinges.
time and make sure the angles are the same. See
video for how I would typically install the middle arm Do not over-tighten the screws or it will be tough to
and work my way to the top and bottom arms. move the boxes around.

Important: Make sure the wood screws used going I used a softwood from pallets so I made sure to pre-
into the boxes ARE NOT Pre-drilled with the same size drill so my layout would be accurate.
hole. This will allow for the hings arms to work as

Download
https://www.instructables.com/files/orig/FL1/CFOR/KAWI9GD4/FL1CFORKAWI9GD4.mp4
…

Step 5: Assemble Hinge Arms to Boxes

3-Tier Toolbox: Page 5
Follow your layout and put the Hinge arms on the boxes per your layout.

Do not over-tighten the screws. I used brass ferrals to help keep the screw loose relative to the boxes. This is not
necessary but would be helpful to avoid the screws from getting loose with time.

Step 6: Fabricate and Install the Cam Lock

This was a little tricky as you need to make a bunch of
small cuts to make this little cam lock work. I also
recessed the back plate a little to receive the cam lock
mechanism. the diameter of mine is actually 1" and I
used a 1 1/4" forstener bit to carve out the female end
on the back plate.
I would encourage someone to make a better
mechanism here. This works but it's not the best part.
of this build. I really got discouraged when designing
this and de nitely made this cam lock to just get it
done.

3-Tier Toolbox: Page 6

Step 7: Add Straps and Accessories

I used a mixture for grommets and washers with 5/8" screws to install the straps holding my drill and impact gun.

Using the sharp tubing in the grommet kit, I chucked the 3/8" tube to my drill and it makes holes a lot quicker than
using a hammer.

This is actually one of my favorite feature of this box. As I like to have my impact and drill available for quick access.

Step 8: Fill Up With Your Stuff and Start Using

3-Tier Toolbox: Page 7

Thanks Instructables of pushing me to nish this In this case, precision is more important than
project. accuracy.

For anyone interested, I uploaded my sketchup le for
your use.
I did not include much dimensions as it's not actually
that important. I measured the boxes when I made
them but other than that, I just made sure that the
spacing for the hings arms were the same.
Feel free to reach out to me if you have any questions.
I also video'd most of the construction of this, but I
de nitely lack the motivation to edit and post. With
enough encouragement I would de nitely start
editing.
Thank you for reading.

Download
https://www.instructables.com/ORIG/FQM/ORF5/KAWI9J09/FQMORF5KAWI9J09.skp
…

Very nice work, I really like the result. Well done : )

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