Building my own Toolbox

[GaryGearloose]

Hi to all,

as i told in the „introducing yourself“ thread, i‘m here to find some new ideas and get some help.

Actually i‘m looking for some new toolboxes for our employees. In Germany it‘s a bit different to the USA. Our employees get the tools and Boxes provided. They don‘t have to buy them thereself.

So i have to pay for all of these boxes.
I want to get the same box for each.
But the decision isn‘t that easy.

I appraised many toolboxes from german producers. But the quality is not what i expacted.
The load capacity is low and the wheels are fragile.
The drawer slides are also not made for huge load.

So i asked my Snap-On Dealer... But as i expected, these boxes are really expensive. And the color i want to buy is not in stock and not with good discount.

So I figured, why not just build my own toolbox. Just the way I like it?

I studied automotive engineering and therefore I know a lot about Cad programs and the like.
The whole thing is also a pipe dream and here I try to find ideas for the ultimate toolbox.

To the box itself, this should, unlike in the USA, not be the bigger the better, but should bring everything important in a small to normal space.

Dimensions, which are also flexible in our workshop, should be around 1m on 70cm (40 x 25 inches).
Does this size also play a role for you, or do you mainly have the extremely large tool trolleys?

I am curious about your ideas and hope that we can design a cool tool trolley with top quality together.

When it comes to production, I'm thinking of laser-cut sheet metal bending parts.
These could then be joined with rivets and/or spot welds and body glue.

The whole thing should be designed in such a way that even a hobby mechanic in his garage could assemble it.
Then anyone can build the tool trolley at home.

I look forward to your answers.

Best regards Marc

 

[nadogail]

An "old timer" told me; when I asked him what sized tool box should I buy?

His response "Buy the biggest tool box you can afford, and you will eventually fill it"

 

[GaryGearloose]

That's also a statement.
But as I said, here in Germany things are a bit different.
If you would see the boxes we have in daily use, you would probably laugh at us.

That's just because the employer provides the tools. A lot of things that are not used daily are therefore stored in cupboards and shelves in the workshop and are not pushed around by every employee. Also the workplace is usually not always exactly the same. Therefore it is important to ensure a certain flexibility with the box. Also, the space between the lifts is sometimes a bit narrow. With a 100 inch crate you would be completely out of place here.

What I also noticed is that you never have foam inserts in your crates but always the outer packaging of the tool. I absolutely want to have the inserts cut later so that everything is clean and tidy. Also, each box is then constructed in exactly the same way and an employee would also find his way around with a box of colleagues.

 

[alberto]

I suggest looking at Lista Cabinets. They are customizable and can be made in various (including I believe custom) colors. High capacity, high quality. The only downside is that they are expensive, although less expensive than Snap on and they are, I think, a better box.

 

[MushCreek]

What are you going to put in the boxes? I'm a tool and die maker, and have a lot of heavy tools made out of solid tool steel. Way, way heavier than mechanic's tools. I used a cheap Chinese box for the last 10 years, without any problems. Here in the States, we have Harbor Freight, who sells inexpensive tools from China. Most of it is garbage, but their tool boxes are actually pretty good for the money. Probably not available in Europe, though.

 

[matt_i]

Biggest thing for me is the casters and almost more importantly their connection to the structure of the box. I have a lot of Craftsman cabinets, OK but I have them loaded, also with machinist & hand tools. I had a caster pull out once (self-tapping sheetmetal screws let go) while rolling it in the shop and I crashed the whole thing in fairly dramatic fashion trashing a couple of drawer slides.

I also suggest making friends with a press-brake shop. Using thin sheetmetal is the way to go for low cost but stiffening it is going to require bending ribs and angles and channels into the flat steel and so forth into improve its structure.

 

[CraigStu]

I think making a box is going to take way more time than it is worth. I could see making one for myself as a fun project but more than one- oh heck no. I can't imagine that you can't find a suitable box but then I am not in your country. One option for you would be to buy a box and then replace the casters w/ better quality. I would probably build a rectangle of angle iron, bolt or weld the casters to it, and then set the box into it. Or possibly a flat steel sheet maybe 1/8 in thick casters under and box on top. Either method would increase the structural integrity if the box itself is not quite what you would want.

 

[JamesW84]

Most mechanics around here either have a smaller tool cart like you're looking to build that they push around or a larger box as you described that they walk back and forth to. Some have both. The big box is their "cuppord" that they keep the lesser-used tools in.

A couple mechanics I know have carts (not specifically made for tools) that they store their tools on. They've added screwdriver holders, etc hanging off the side. You should have a look at Adam Savage's custom tool holder:

 

[GaryGearloose]

so first of all many thanks for the active participation.

Yes exactly James, such a box to drive around is exactly what we have in Germany as a normal box.
I would like to build something like that.
Of course I am aware that this is expensive and probably won't come any cheaper afterwards. But something appeals to me such a project also...

Let's think about it:
What does such a toolbox need?
- Drawers in different heights
- flat storage surface (here you can find boxes with plastic tops. These are partly already equipped with compartments etc. Quite horrible)
- sockets
- USB socket for mobile phones, tablets, etc
- Storage area for spray cans, cleaner...
- Space to hang up a charger

Technical design:
- 4 wheels (2 rotating and 2 rigid)
- stable box made of folded metal sheets
- extendable telescopic slides
- Possibly an automatic cable drum for the sockets

Can you think of anything else?

 

[GaryGearloose]

The boxes will later contain normal tools such as screwdrivers, ratchets, nuts etc. but also special bodywork tools such as chisels, large hammers, files, grinders etc.

 

[GaryGearloose]

What are you going to put in the boxes? I'm a tool and die maker, and have a lot of heavy tools made out of solid tool steel. Way, way heavier than mechanic's tools. I used a cheap Chinese box for the last 10 years, without any problems. Here in the States, we have Harbor Freight, who sells inexpensive tools from China. Most of it is garbage, but their tool boxes are actually pretty good for the money. Probably not available in Europe, though.

The boxes will later contain normal tools such as screwdrivers, ratchets, nuts etc. but also special bodywork tools such as chisels, large hammers, files, grinders etc.

 

[CraigStu]

When I worked as a tech I had a similar setup. Main box against the wall and a cart I pulled around. The one I pulled around was a lot like this except it also had a top that could be installed w/ a padlock.
https://www.webstaurantstore.com/ru...m_term=1100400186606&utm_content=2 Month Sale
Probably the best thing about it was that it was plastic so a light bump into a car did no damage. Would something like this work for you?
https://www.uline.com/Product/Detai...f7&gclid=CM-JlYSO6-cCFXSPxQIdAnQOFg&gclsrc=ds

 

[ZRX61]

You're going to end up paying more than you would have done by going with SnapOn.. & all this effort just for toolboxes in a body shop?

 

[brownbagg]

i always wanted to build my box, maybe get something you like and copy it. the drawers would be the hard part, keeping square, need a good bender, not no cheapy but a good high dollar bender, good cutter, so that would be a decision on thickness, then good drawer slides.

it can be done, and it be a nice project, be fun if you have the tools.

tv show "how its built" had an show that they showed how snap on boxes was built

i think it be fun

 

[ZRX61]

I appraised many toolboxes from german producers. But the quality is not what i expacted.
The load capacity is low and the wheels are fragile.
The drawer slides are also not made for huge load.

Standard box, just build a decent chassis for it...

 

[regguy1]

Here's my tool box:

Review video (no tools in it)

Organization video (with tools )

 

[GaryGearloose]

Standard box, just build a decent chassis for it...

Okay, that's a sturdy rack.
Looks like the box is often loaded with the forklift?

 

[sberry]

I might put wheels back on if I really had to roll it but I use a pallet jack. This is for the overflow and seldom used,,, its loafed.
I have built all kinds of boxes, not so complicated as a full drawer box but aint no how no way with the likes of the HF which is so good, so cheap, well finished and paint would cost more than that.
This is a place to be practical, you are doing this for work, for fleet, different if you need an expensive hobby. Same for all that foam cut out shat. Put some mat in and toss the stuff in.

 

[ZRX61]

Okay, that's a sturdy rack.
Looks like the box is often loaded with the forklift?

The owner added that frame, it started out as a standard Craftsman box with regular castors. Fork lift pockets were added so he didn't have to push it around a 620,000sq ft hangar, or drag it across the ramp to other hangars.

 

[pvanderlugt]

Standard box, just build a decent chassis for it...

Looks like that one is ready for a road trip!!!
Pete

 

[isb cornbinder]

I used to build toolboxes. I have the shop and the sheetmetal machines to do it.
It is not possible to build any toolbox for the amount it costs to buy one. This applies to all of the boxes, including the very expensive SnapOn boxes.
I do not have any pictures of the major boxes.

 

[PWC Repair]

Have you checked with uktoolcentre? They have some nice midrange priced boxes and I'm sure can easily ship to you. Or maybe cut out the middleman and contact a manufacturer, see if they'll ship direct to you. There's one called e-make in Taiwan that makes some nice looking stuff.....they MIGHT be the ones building the HF toolboxes.

 

[John in OH]

Standard box, just build a decent chassis for it...

I worked in the fossil power generation industry for 35 years and this (^^^^) is similar to the tool chests that were provided to each of the maintenance mechanics at our power plants.

Good quality commercial boxes (usually Wright or Proto) were purchased and then the casters were removed and the box remounted on a solid carriage. Each mechanic was provided a set of standard tools by the company, but the mechanics were permitted to modify the boxes to meet their specific preferences. That usually included side-mounted tool racks, electrical outlets with extension cords, etc.

Heavy tools, specialty tools, and lesser-used tools were available as needed from a central tool room.

 

[clubairth]

How about the 5 drawer Harbor Freight boxes ?
They are shockingly good and cheap enough to replace if they get damaged?

Recently they went to the series II versions and made the drawers 22" deep instead of the previous 20" deep drawers.

I have 3 dedicated to different types of work. One for regular mechanics tools. A welding cart and a body work cart. Leave my big double stack box where it is and work out of the 5 drawer roll arounds.

This is a very efficient way to work since I also have a 2 post lift.
.
.
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[Bogie1632]

GaryGearloose,

By chance have you looked at Fami Storage Systems? I know they have a distributor in Germany. When I was station at Ramstein AB we purchased many cabinets and from what I recall they were much more reasonably priced than others we priced from Snapon, Lista, and Vidmar. They had many options and styles available.

V/R
Bogie