Here's my version of a portable toolbox.
Took my old Sears blow-molded toolbox off the shelf the other day to throw in the truck anticipating a repair, and the sockets were so loose and falling out I decided I'd build a new portable toolbox for the truck, junkyard and dune trips. I work occasionally in a friends metal fabrication shop, and while his metal working tools are 'finest kind', his mechanics hand tools can be challenging. I always feel funny about using someone else's hand tools so I'll be able to take this with me to work on my projects there.
I started with the smaller Pelican knock-off from HF (Apache?) with interior dimensions of 9"x12" and about 6" deep. I used the interlocking foam they sell and some scrap aluminum to make a series of stacking trays to fit the box. I know a lot of people aren't crazy about foaming their tool box, but in this case it helped me get quite a bit of toools in a reasonably small box.
Here's the box. I took the foam that it came with and used the 1/2" anti-fatigue foam that they sell for like $8 for four squares.
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Two layers of foam are glued into the top of the box and that's were the tools that I need most frequently are located. About half of the things I come across can be addressed with a Leatherman, so I put that in the lid (it is usually in the console, door card or glove box in the truck where I have to look for it) One of the new HF Bauer LED lights is there too, and installed so you can swing the LED wand out and illuminate the toolbox. A pair of dykes. electrical tape and some single edge razor blades are handy there too. I keep about $4 of quarters too - always forget they want money to get into the junkyard. The dykes kept falling out when I opened the lid, so I glued a magnet into the foam to hold them in place.
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The first layer is screwdriver, allen and Torx bits. I didn't want to load the box up with bulky screwdrivers, so they are almost all .25" hex that I can drive with a 1/4" socket. The HF digital calipers were cheap with a 20% discount, so I threw one in the top tray too, and just pried the foam out of the case and put it in my toolbox.
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The next layer is the 'brute force' tools - vice grips and crescent wrench along with a pair of long needle nose pliers I found once in one of my junkyard adventures. Note the finger holes in the trays to facilitate getting them in and out of the box.
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Next are the box-open wrenches - they're cheap HF sets, but they seem to work well and get good reviews. At $7 a set, if I lost one or the whole tray it wouldn't be any big deal
The metric............
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The SAE...........
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The bottom of the box contains sockets. I seldom use anything other than 1/4" or 3/8" drives, so that's all that's there. The sizes overlap with one or two sockets to keep the socket count down, but I do have regular and deep, I splurged and bought two of the HF flex head 72T ratchets as they seemed a step or two above the Craftsman I'd been hauling to junkyards for years. Didn't have enough socket size labels for everything so I'll have to order a couple more sets.
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Here's all the removable trays laid out on the shop toolbox.....
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I suppose all-in I have about $100 in the box. None of the tools are too expensive, and if I lost a tool, a tray or even the whole thing it wouldn't be the end of the world.