box building/box filler/butt joint

[tpolley]

i'm looking to build a portable/carry type box for my power tools and another box i can mount to the back rack of my 4-wheeler. it's gotta be durable. in the past i've used 3/4 inch ply wood. i have found that i have a hard time cross-cutting the ply wood without it splintering all over the place. i've tried a finer tooth blade and it helps but its still not quite right. anyhoo, i'm thinking this time i'll use 1x10's or 1x12's or the like. in order to get the desired width i'll have to butt two pieces together to make one wider piece. the only two ways i know of doing this are using a bisquit joint or the small peg or dowl. will either of these provide a durable joint? i don't need to be able to park a car on it but i want it to be able to get the crap knocked out of it without comming appart.


also what about filler for a power tool box. i thought about foam but last time i went to the fabric store to buy foam the dense grey stuff was so expensive it wasn't worth it for the project i was working on.

thanks in advance.

[metal1313]

your best bet is actually to score the ply on both sides. i score with a utility knife, then use a standard gen purpose blade to cut a very shallow score into one side of the sheet, then a full depth cut on the other side.

ive also found that for me, i get better results with as little extra blade depth possible to make the cut due to less friction

[kbs2244]

The old way to join boards to make a wide panel in non-furniture builds was to lay the boards next to each other and use a 1x2 crosswise to the seam screwed into each board.

You used at least one at each end of the panel and maybe more in between to stiffen it up.

You will see a lot of chests and tool boxes built this way at antique shops,

[sstruckguy]

The larger(24 qt) milk crate type boxes have always held up well for me:



If you need a cushion or liner, I would suggest an inexpensive eggshell.

If you are needing something more waterproof, Big Lots seems to always have some pretty cheap plastic tool boxes available.

These options will save you money as well as a tremendous weight savings.

[southpier]

Originally Posted by metal1313

....as little extra blade depth possible to make the cut due to more acute angle of the blade's teeth

and if you're using a table saw, good side goes 'up'. circular saw or jigsaw, good side goes 'down'.

[mbatarga]

Any modern wood glue will edge join solid wood just fine by itself. The only purpose for a dowel or biscuit joint would be to aid in alignment or assist in assembly for clamping. In your case, for your project, that likely not needed. Just be sure to spread the glue evenly and clamp the boards for at least several hours for the glue to do its job.

[Mattlt]

Masking tape along the cut line usually helps a lot too.