Note: This article is part of an ongoing series about the details of tool chest construction.
When building a tool chest, it’s tempting to get to the dovetailing as soon as possible. However, the work you do before the dovetailing is more important in the long run. (Even crappy dovetails hold nicely after hundreds of years.) And so I’m afraid we’re going to talk about a topic that bores people to tears: stock preparation.
Stock Selection I use white pine for tool chests whenever possible. It’s lightweight, easy to work and plenty strong. My second choice is poplar (Liriodendron tulipifera), which is dirt cheap here in Kentucky. Poplar is easy to work and available in wide widths. The major downside to poplar is its smell. Some people find its odor to be as pleasing as dog poo. It doesn’t bother me.
Crosscut in the Rough After I purchase my stock, I immediately crosscut it to length while it’s still rough and sticker it for a couple weeks in the driest area of my shop. I check the moisture content with a meter to ensure I don’t encounter any surprises. Boards move the most while losing their last few bits of moisture as they reach equilibrium. So let them do this while in the rough.
Making Panels Tool chests are painted, so you don’t have to fuss over the grain patterns in the panels. But you should fuss over the grain direction. After jointing and planing the boards to size, orient the boards in each panel so the grain direction runs the same way.
Also, and I know this will make people howl, orient the heart side of the boards so they will face the outside of the tool chest. Doing this will ensure the corners of your tool chest will stay as tight as possible. That’s because when boards warp, the bark side becomes concave and the heart side becomes convex. So putting the heart side facing out will force the corners of your carcase together. If the bark side faces out there is a danger that the corners will open.
This is a fine detail because the carcase is enclosed by dovetailed skirting. But you might as well do it right.
The heart side of all your boards should face out. I know this is blasphemy among modern woodworkers.
Squaring and Planing After your panels are glued up, square them up. Don’t trust your machines to do this. Check the ends with a reliable framing square and tweak the panels with a handplane. Then remove all the machine marks on the boards’ faces with a handplane. Do this before dovetailing.
If you handplane your panels after dovetailing, you can create gaps in your joints. You can plane the tailboards without creating gaps, but planing the pinboards after the joints are cut is asking for trouble.
With your panels square and clean, you are ready to cut dovetails. Details on that operation next.
When I wrote “The Anarchist’s Tool Chest,” I didn’t think a single person would actually build the chest shown in the book. That’s why I greatly condensed my construction instructions, and I eliminated chapters for a traveling version and a Dutch chest.
Six years later, building these tool chests comprises a significant portion of my income. This is both surprising and heartening. Yes, wall-hung tool cabinets and racks are great – no argument. But there is something about a tool chest that appeals to certain woodworkers.
I have been working out of a tool chest since 1997 and – after using racks and cabinets – am deeply satisfied with my choice.
This week I have launched into building two full-size chests for special customers. Both chests will have a full suite of hardware from blacksmith Peter Ross. Plus lots of details I’ve been itching to try, and some new ideas from the customers that I’m quite excited about.
I’ll document their construction here – not so much to generate additional business (I have 14 commissions lined up for 2018), but to make up for the lightweight instructions in the book.
First up: Choosing lumber and gluing up the panels. Look for it soon.
Memory is a damn funny thing. It can be as impossible to hold onto as a handful of water. And yet you can drown in a cup of it.
Today I went to pick up a load of sugar pine for an upcoming tool chest I’m building for a customer and got whacked upside the head by a pointed 19-year-old memory.
Since the closing of Midwest Woodworking a few years ago, I’ve run dangerously low on my stock of sugar pine and didn’t have enough to do the job. Enter Kevin McQueeney, an Indianapolis woodworker who offered to help me purchase a load through his local supplier.
After some back-and-forth, it became obvious that the sugar pine was going to come from Shiels Lumber here in Cincinnati. It’s an old place in the neglected industrial lowlands of the city, about a half mile from the foundry that makes our holdfasts.
Hearing the name Shiels was like waking up from a deep dream. How had I forgotten about this place?
When I started at Popular Woodworking magazine, the first significant project I was permitted to build was an interpretation of Benjamin Seaton’s tool chest. My boss made me change a lot of details so it would be accepted by the magazine’s readership – the corners were assembled with finger joints instead of dovetails, and the interior till had to be simplified.
But despite these compromises, it was a major piece and the first cover project of my career.
The first hurdle with the project was finding white pine that was thick enough for the job. One of the associate editors took me to Shiels, a wholesale yard that is off-limits to retail customers. We loaded up a truck with the pine, and I remember looking up at a weird sign painted on a building that towers over the yard that reads: “This Way Sinners.”
I wondered about the sign 19 years ago. And I had the same sense of wonderment as I loaded my pine today and looked up at the same sign. Thanks to the Internet, I dug up a history of the sign behind the guy who had it painted in 1896. You can read it here. It involves a trip to the Holy Land, a misplaced photograph and hieroglyphics. And the story ends with: “Most salads require a little pinch of salt.”
And the pinch of salt in this story: After 19 years I’m back to building tool chests, buying pine at Shiels and wondering which way this sinner should go.
Though you might find this odd, a sizable chunk of my commission work is building tool chests and workbenches for people.
When customers first approached me with these jobs, I resisted. My response was: You’re a woodworker; you can build your own for much less money. But after further discussions, I realized that I could say this to almost any aspect of the craft.
Don’t have a shop? You’re a woodworker – build one.
Don’t have a handplane? You’re a woodworker – build one.
Don’t have a wooden floor?
Don’t have a dovetail saw?
And etc.
When it comes to the great Time Vs. Money Scale, some of us have more time. Others have more money. (Few of us have both or neither.) And so I started making workbenches and tool chests for customers. This also conveniently drained my supply of half-built tool chests and workbenches in my garden shed that were left over from classes.
For woodworkers who can’t afford a tool chest from me (they cost $2,000 to $3,500 depending on the options), I encourage them to buy a vintage tool chest. In the Midwest, South and East, almost every antique store has a chest to sell. You just have to tune your eyes to see them. Typically they are holding other items – plates, glassware or creepy dolls – and so they are easy to miss.
They often show up in local auctions – an Amish auction near me usually has a dozen chests each year.
And the price is right. About $200 to $400.
Most of them need to be cleaned up. The tills are worn out and need to be repaired. Mouse holes are common. Rot in the bottom boards is a frequent feature. Dislocated hinges and a pink paint job round out the list of things you’ll want to remedy.
But it is a great alternative. Most chests can be fixed up with a day of work in the shop. And you will get a gold star in woodworker heaven for saving a tool chest from its doom as another plant stand.
There are several ways to make the lid. Some work great. Some are quite stupid. Let’s start with the stupid ways first. When I built my first tool chest, I copied the construction of the lid from an original. It was a single flat panel of wood trimmed on three of its edges with narrow stock that would interlock with the dust seal attached to the shell.
If I remember correctly, I think the lid worked as intended for about a week, and it has been bockety ever since. The first problem was with the lock strike, the brass plate mortised into the underside of the lid. Because the lid was a simple flat panel, the top shrank a bit, which moved the lock strike.
One day I tried to lock the chest, and the mechanism wouldn’t engage. In fact, it just pushed the lid up off the dust seal. So I filed the opening in the strike until the lock worked again. About six months later the top expanded and the lock wouldn’t work anymore. This time, filing wasn’t going to fix the problem – I would have filed away one wall off the strike. So I resigned myself to having a chest that would lock only during the dry season.
Then the top warped.
Because the top of the lid was the bark side of the tree, the warping made things worse. The front and back edges of the top curled up. And the movement was enough that the strike couldn’t be struck by the lock mechanism.
But my troubles didn’t end there. When I built the chest, I wasn’t a total doofus on the topic of wood movement. I knew the lid was going to move, so I selected a species that didn’t move a lot once it was dry. I used white pine. And when I applied the trim around the lid, I did everything I could to minimize the problem of cross-grain construction. The trim pieces on the ends of the lid were the problem. They had to be nailed onto the end grain.
This is a problem. Nails and screws don’t hold as tightly into end grain as they do into face grain. So I wanted to introduce some glue into the joint to help things along. of course, glue doesn’t want to stick to end grain. And when you glue long grain to end grain, the end grain will try to bust apart the joint as it expands and contracts with the seasons.
There are several solutions to this problem. Some involve a sliding dovetail. others involve screws in elongated slots. The simplest solution is to glue and nail the trim on at the front of the lid and use nails only at the back part of the lid. This was the technique that the original builder had used. The theory here is that the glue and nails will keep the trim secure and tight up at the miters, and the nails at the back of the lid will bend to allow the lid to move.
It’s an interesting theory and one that sometimes works. It sure didn’t work for me, however.
The trim is barely holding on to the lid. The miters are open and flopping around like a broken finger. And the lid’s joints look like crap. I want to remove the lid and rebuild it. I should remove it and rebuild it. But I really like the way the paint has aged on the lid, and the broken joints are a constant reminder about the wily ways of wood.
So when I set out to build a new chest, I looked for other historical examples that would be more durable. The vintage pine chest I bought had the trim glued and pinned to the underside of the lid. This had the advantage of removing the end grain from the equation. All the joints were long-grainto-long-grain. But this is still a bad way to build a lid. Instead of the trim coming loose, this lid is designed to split. And boy did the lid split. There is a 3/8″-wide canyon right up the middle of the lid, which invites dust inside. It’s such a problem that the best solution was to cover the split with tape to keep the dust out.
So don’t build your lid like that.
I took a look at other chests. Duncan Phyfe (1768-1854) was a smart guy, one of the most celebrated 19th-century cabinetmakers. And his tool chest, now at the New-York Historical Society, is filled with all manner of amazing tools. But the lid is curious. It’s a flat panel with breadboard ends. While the lid worked out for Duncan, it might not work out for you. Breadboard ends definitely can help things and improve the way a dust seal will attach to it. But it still won’t help things when you add lock hardware. It’s going to move forward and back as the panel expands and contracts.
Better lid. A frame-and-panel lid with a raised panel is about as robust as you can get without adding lots of weight.
Really, the best solution is to build the lid as a frame-and-panel assembly (or use a slab of Formica). This confines almost all of the wood movement to the panel that floats harmlessly in the middle of the rails and stiles. And if you choose quartersawn wood for the rails and stiles, they will barely move at all.
So you could build the lid in the same way you would build a raised panel door. I would recommend using through-tenons on the rails. But what about the panel? You want the panel to be thick and stout because it will take a beating. So the joint between the panel and the lid frame is critical. You don’t really want to thin down the edges of the panel as you would when making a door panel. Thin edges will weaken the panel.
The old-school solution here is to plow a groove in the edges of the panel so the panel will interlock with the rails and stiles. This will keep the joint between the panel and frame as stout as possible, and the panel will be raised above the frame of the lid.
There is no downside to this approach. There are no weak spots on the lid. There is no significant wood movement along the edges or ends of the lid. So the trim around it will stay put. It is as permanent as can be.
