What would your "90% box" look like?

[AJHD]

Despite the fact I've had some set backs that have extended my initial time frame, my living situation still remains very "questionable/temporary."
As part of this reality, I've put most of what I own into storage and I've sold/donated a fair bit as well. But while I continue to downsize, my current situation and past experience of having moved several times, has me thinking a lot about the amount of stuff I own. I admit that I've failed terribly at being a minimalist, at least when it comes to tools. As such, I have acquired way too many tools over the years. What started as a profession turned hobby, is now near a full blown addiction (but that's another thread for another day). Anyway...

A few years ago Watch Wes Work put out a video on a cantilever tool box setup that he called his "90% box" for repairing/servicing CNC machines. Another YT channel I watch is called Last Best Tool and Doc has several videos now on exploring, researching and building his minimalist overland tool kit.

While neither of these exact scenarios apply to me, I can't stop thinking about putting together my own "90% box." Although I can't contain everything in a single box (due to size and weight), I'm trying to decide what tools I want to keep with me and what tools could stay in storage. I need something portable and something that takes up as little space/weight as possible.

So, what would your "90% box" look like? What is necessary, essential, fundamental, basic and what is just nice to have? What is used for every job or otherwise actually get used, and what is rarely used or maybe has never even been used at all? What about duplicates or multiple ways to accomplish the same task? What about power tools that require a battery & charger, or need to be plugged into the wall? What tools are automotive specific and what is more general purpose? I find myself asking more and more questions as I dig myself deeper down the rabbit hole.


Disclaimers;

#1. I understand this is very subjective to what you work on, what you do with your tools... A "90% box" setup around automotive repair will look vastly different than that of an electrician or plumber or industrial mechanic. My focus, my needs, my use of tools for this project is 100% automotive repair.

#2. For this project, I'm not considering shop equipment, supplies or fluids, etc. I'm also not considering spare parts, things like that. All this stuff will stay in storage until needed for a specific task or otherwise will be kept separate from this project (maybe in addition to).

#3. Keeping the previous statements in mind, this NOT being setup as an EDC, an emergency kit or something I'm keeping in the car in case I break down on the side of the road, etc... It's also NOT being used as a mobile mechanic setup or anything else of the sort. It's simply about prioritizing tools and only "carrying" the essentials.

 

[AJHD]

*Reserved post for pictures to be uploaded later*

 

[KnurledNut]

@AJHD
What kind of box are you planning on using? That will greatly affect how much or little and even how long items can be recommended.

 

[Professional Tool User]

If 90 percent of my tools got stolen during a break in but I was allowed to choose what didn't get taken, I'd probably choose the stuff that is already in my Snap on roll cab plus or minus a few items. I'd be left with my best pliers, screwdrivers, hammers, punches and chisels, pry bars wrenches, ratchets, impact sockets, cordless tools, air tools, multimeter, test light, assorted accessories, and frequently used specialty tools like oil filter wrenches.

 

[ItsNemo]

I'm currently in the process of putting together a general hand tools service bag...so screwdrivers, pliers, basic electrical tools, small socket set, hammer/pry bar/punch, gloves, eye/ear protection, knife, light, small assortment of fasteners, etc.

Basically something when my neighbours ask me for help with something, rather than having to grab bits and pieces out of my main box, putting them in a tray, and then making 5 trips back and forth to the house...I can just grab the service bag and have most of what I'd need.

I'd like a drill/impact/screwgun in there, but will probably carry one of those separately...just as then I have to keep batteries charged and pretty bulky and expensive to have a drill in there all the time.

 

[humber2]

My 90% portable toolbox will do most work that doesn’t need a jack so it’s only got tools and 3/8” sockets to work up to 13/16” or 21mm or 7/16WW being 14mm spark plug size.

Tools above that size start to get heavy and are needed occasionally for specific known tasks, like I used a 15/16” DBE from my rollcab to wrench the crankshaft nut to get to the points on a sparkless Briggs & Stratton engine last weekend as our Spring growth lawn mowing season needed action.

 

[rsanter]

I helped my dad with this several years ago. He has lots of tools for doing just about any job.
To make things easier and faster for him I helped him out together a carry box for fixing sprinklers, another one for general plumbing, and one for general/household repair.

These cover 90% of what he does on his own anymore.
When I help with fixing cars he brings the car to my place or at his place we are in the garage near the toolbox so no big

Personally I have a general repair tool bag for home fix stuff

 

[dchawk81]

My 90% I guess is what you could call what I carry in my truck with me every day.

100-some odd sae/metric socket and ratchet set, 100 some sae and 100 some metric 1/2" impact socket sets, impact wrench, grease gun (both M18 cordless), drill, air hose, air chucks, gladhand adapter to use the truck's onboard tank and compressor, multimeter, screwdrivers, vise grips, pry bar, BFH, come-along, security torx bits, knipex pliers, snap ring pliers, and some smaller things I can't remember in a box under the seat.

Basic stuff to fix almost anything reasonable en route.

Won't be doing a truck stop overhaul or anything but it covers most of the daily encounters.

 

[AJHD]

My 90% portable toolbox will do most work that doesn’t need a jack so it’s only got tools and 3/8” sockets to work up to 13/16” or 21mm or 7/16WW being 14mm spark plug size.

Tools above that size start to get heavy and are needed occasionally for specific known tasks...

I'm working off the same idea. I'm going with 1/4" and 3/8" sockets up to 22mm (the caliper bracket bolts on my Nissan are 22mm). I'm also going to up to 22mm on my wrenches.

But I'm trying to avoid anything larger due to size and weight. No reason to carry 1/2" sockets or anything above 22mm. I'm also trying to avoid specialty tools and carry only basic diag tools.

 

[geartow]

this is a difficult question, my 90% at home is difert than works. At work in the shop a HF 5 drawer cart covers my needs. at home a nice hand box covers them. on the road at work 3 large hand boxes/bags. i work as a heavy wrecker driver.

 

[milkovich]

I have one in the pickup truck, it's a bag, and it's mostly the cheapest passable tools I can find so that I can break, bend, lend, or even laugh when they're stolen. One sad decision I finally had to make was all metric, no SAE. It's just too heavy (and I have different roadside tool bags for the muscle cars.) I also have one pouch pocket with all the receipts for all the tools so Walmart/HF/HD/Amazon/etc will warranty them after some "creative" use like using Torx sockets as extractors and there are some zipties, electrical tape, and other consumables floating around too. I still need to add some line wrenches and a small hacksaw.

 

[kbeefy]

I have put together kits for a couple different situations in the past. I have done a couple 10000 mile roadtrips in some very remote areas and had to divide available space/weight between tools, food, camping gear etc...
I was also a field helicopter mechanic for a long time and had to bring enough tools with me to keep things running.

One thing that helped me lighten my tool load was coming to grips with what repairs I would actually try to complete in the field, and what tools would possibly be supplied with whatever part that had to be sourced. I'm not carrying an extra 100# of tools for a job that I'll need a part shipped to me anyways.

You said Nissan so SAE tools are largely unnecessary. I do still carry an standard depth SAE 1/4 socket set, there are lots of small hardware in the wild that is SAE.
1/4 metric standard depth sockets
1/4 ratchet + 6" extension
3/8 sockets 10mm-19mm
3/8 ratchet and 6" extension
1/2 sockets 14mm-22mm (make sure to have the proper socket for lug nuts and axle nut)
1/2 ratchet and 9" extension (I know you said 3/8 only, but 1/2 ratchet survives longer when hitting with a hammer)
Combination metric wrench set 6mm-22mm (I try to figure out what the largest fastener on my vehicle is)
10" knipex plier wrench
Ratcheting screwdriver with whatever bits you might need
Large regular screwdriver that can double as a prybar
Multimeter with probes and alligator clips
Wire stripper/crimper

I like to have a 3-5# hammer, but a rock will do in a pinch.
I always have a flashlight, if you don't then add one.

Also, a credit card takes alot less space than any tool. Some things we left because the likelyhood of needing them was very small and purchasing if the need arose was relatively cheap. We applied that mantra to alot of our packing.

 

[Moose-LandTran]

A few items missing but it generally looks like this:



Worked for me for 4 years of roadside assistance. My mobile electrical test stuff lives seperate in a tool bag.

 

[BarrelRoll]

Here's my "drift bag" I bring just about everywhere at a gold mine to work on anything without wheels or tracks (mill, crusher, pumps, concrete pumps, water treatment plants). You can do a lot with a little. I can get by without sockets for most things.

-3lb wilton hammer
-proto side cutters
-chanellock flush cuts
-2x mayhew 14" line up/ pry bars
-Small snapon punch/ chisel set
-Vise grips
-Medium knipex
-Wire brush
-10 and 15" adjustable wrenches
-Williams super combo wrenches 5/16-3/4" and 15/16"
-Standard and metric allen keys
-Magnet on a stick
-Stiff hyde 1 1/2" scraper
-snapon right angle mini pick
-Tefflon tape
-Electrical tape
-Williams screw drivers, 3x flat head, #2 phillips

Not shown
-16" snapon straight striking pry bar to replace my long 5/8" chisel
-Mayhew brass was replaced with snapon bronze after I turned the mayhew into a banana

Not pictured is a small pair of knipex, a torch striker, an 8" adjustable, a utility knife, and a tweaker (small flathead pocket screw driver) in the front pocket of my bibs.

 

[AJHD]

A few items missing but it generally looks like this:



Worked for me for 4 years of roadside assistance. My mobile electrical test stuff lives seperate in a tool bag.

I've seen that in another thread. I need to get a cantilever box like that. I think it's nearly perfect for this concept.


@ kbeefy: You make some good points.

As for SAE, yeah I don't own anything SAE these days. I certainly don't carry them. It's been years since I touched an SAE bolt/nut on a car.

Unfortunately my Nissan also has too many aftermarket parts on it. So just carrying 8, 10, 12, 14, 17 and 19mm isn't an option. I know for a fact there is 13, 15 and 16mm bolts/nuts on my car.

Since I've got 3/8" up to 22mm, I won't be carrying 1/2". Largest size I know of is 22mm for my caliper bracket bolts. Anything 1/2" would be only for lug nuts (19, 21, 22mm) and separate from this kit. I also won't be doing suspension work. I sold my suspension tools anyway.

 

[Zewnten]

My previous 90% box looked a lot like moose-land's. Mine held in a cantilever box:
18" 3/8 ratchet
6" 3/8 ratchet
3/8 shallow 12 point sockets with various extensions up to 1/4 to 1, 10mm-19mm and 8mm
wrenches to match socket sizes
3/8 dr crowfoots metric: fuel line sizes and standard: 5/8 to 1-1/4
10" adjustable
groove lock pliers
6 in 1 screwdriver
bent pick
razor knife
snap on wire stripper/crimper
DMM with back probe
circuit breaker fuses
8 inch side cutters
heavy duty needle nose
ball peen hammer
drift
chisel
starter punch
alignment prybar

Now I use a small top chest snap on box, I was going to use a 3 drawer portable chest like craftsman made but it doesn't have enough room.

 

[oldpliers1]

This is what it looks like ( not shown meters sockets hammer and few missing knipex bits )

 

[AJHD]

Interesting setup. Looks geared towards cabling/low voltage?

 

[oldpliers1]

Interesting setup. Looks geared towards cabling/low voltage?

Spot on 240 volt single phase 415 volt 3 phase , industrial and Switchboard/MCC work to 2000 amps ( our grid , 11kv ,415 v , single phase 240 v) four wire supplies. Two phase 3 wire systems were no longer used after 1981 , so all new places have 3 phase 100amps per phase supply that’s domestic. Then 200 -2000 amp per supply commercial. So large factories and malls etc have multiple supplies to meet their maximum demand.

 

[Glemon]

Interesting topic. I will add a few to the things already mentioned. Surprised there hasn't been more mention of vice grips. Having spent a lot of my life working on old,rusty cars, have found them pretty invaluable for stuck or rounded nuts. Can also be used as a clamp the pull or hold things in place while fasteners are inserted or started. For my bag that goes with me in the car I have a medium sized, for home shop can't imagine not having a small, large, and needle nosed.

Stubby screwdrivers. Not used that often, but if full length doesn't fit you don't have many other options, plus they don't take up too much room. Gear wrench combination wrenches, I use them as much or more than my socket set.

 

[VolvoRyan]

It depends on what brand of auto you're working on. Different fastener types can snowball your needs pretty quick.

One "tool" I've come to appreciate is the Wera Tool Check Plus. It's amazing how many funky tools that kit replaces. It's fairly indispensable for interior work.

-Ryan

 

[Odd-job]

Good luck on your quest OP.

I have a 90% cart, but have been trying to slowly pair down what's on it through process of elimination over the last few years based on what I tend to reach for. My main issue is that I work on a wide variety of things from modern Japanese, American and Mercedes vehicles to small engines. Envy those that can really keep a clean setup as I need both metric and SAE on the cart. Have been trying to pair down the socketry to mostly impacts. I make an exception for chrome 1/4 mid depths unless they can make an impact version.

Here's a quick highlights of what I am finding the most used on the cart in case it helps anyone:

• Picks and pry bars - especially the aircraft skin wedge
• Lighting - have several Astro lights I leave on the top of the cart, at least one should suffice
• Silicone tool trays - a lot more durable than the metal magnetic ones where the magnets always fall off
• Small Trash can mounted on the side - not sure if you want your box to turn into a trash can, but this helps prevent it
• Magnetic pickup tools and grabbers
• Zip tie tool
• A master bit set + ratcheting screwdriver - having the bits on hand might save a trip running to the tool box
• Pliers - long angled tip pliers, pliers wrench, knipex cobras, knipex combo pliers, precision pliers, locking pliers, etc.
• Things that speed up things:
  • Impacts and Socketry - swivels and wobbles are nice
  • Cordless ratchets
  • Ratcheting wrenches - reversible ones and mountain flex ratchets
• Hammers - if you are looking to pair down would take one 32 oz dead blow with hard and soft faces
• Combo wrenches (up to 21mm), screwdrivers, ratchets, choose your favorites.

 

[4 FN 27]

This: Main purpose is a Box to wheel around the shop and work out of for the smaller remote projects.

The one on the right.

Still adding to it.

 

[Sumboodie]

I've never seen Wes have machinist videos. I thought he was a mechanic, mostly working on farm equipment.

 

[AJHD]

I've never seen Wes have machinist videos. I thought he was a mechanic, mostly working on farm equipment.

He used to do CNC repair work too.

 

[AJHD]

While I'm still exploring the concept, I've not been able to settle on anything that would resemble it.
I may end up going back to wrenching for a living, in some form or another. So some or all of my tools may or may not go to work, depending on the job. For now, I've split my tools between home and my storage, until something more permanent becomes reality.

 

[jd_1138]

The laws of physics do not compromise, so it's nice to have all the bases covered if nothing else than to make the job go faster with less physical effort. Definitely metric sockets, extensions, ratcheting wrenches (over static), screwdrivers, breaker bars, and pry bars.

It'd be interesting to consider putting tools in a modular system. For example, have your 90% box ready to go at any second, then have a 2nd box with niceties and convenience stuff, then a 3rd box with the luxurious fluff tools that make life even that much easier.

 

[oldschoolcraft]

I love this thread and it's something I've been after for years. I am not a pro wrench, I hardly do much car work, and I never know exactly what I'm going to be working on. Fixing random **** for me or a girlfriend, light car work, I replaced motor mounts recently for the first time in my life, gun work, hobby work, etc.

I have two versions of this. One is a small tool bag that stays in my car. the second is a tool cart at home. Its basically a 90% tool bag for stuff I could reasonably be expected to do when I'm not home. And a tool cart for 90% of stuff I could do when at home.

i hadn't heard of this guys videos before. I watched some, nothing called a 90% kit but I saw some overland videos. Is this the same ones you refer to OP/

 

[Eli D]

Sad to say seems like I’m always short 1 thing even if I have my entire box with me

 

[AJHD]

i hadn't heard of this guys videos before. I watched some, nothing called a 90% kit but I saw some overland videos. Is this the same ones you refer to OP/

See post #25 above. I posted a link to the specific video I was referencing in my original post. Wes calls it his "90% box" in the video.


@ jd_1138; I like the idea of 1st line, 2nd line and 3rd line being applied to tools.

I think my 1st line would be hand tools, 2nd line would be power tools, 3rd line would be diagnostic and maybe specialty tools.

I think it would be impossible for me to fit everything I want into a single box.

Unfortunately auto repair gets more complicated... Floor jack, jack stands, fluids, various supplies (funnels/pigmat/etc), ppe, etc. Those are all in addition to any tool kit.

 

[slimpickins]

I agree with @oldschoolcraft. This is a great topic. When it comes to DIY, I'm a jack-of-all-trades kind of person. My toolboxes reflect this, but still need better organization. The contents have evolved over decades but the system has served me very well. You could say I have a modular toolbox system, generally organized as follows:
General toolbox - Contains wrench sets, sockets, screwdrivers, plier assortment, vice grips, allen wrench sets, utility knife, replacement blades, etc. If I know I will need some tool for a specific job that doesn't normally live in there, I'll throw it in for the ride. Currently this is a small 16" toolbox and I just bought a 24" metal one to replace it.
Plumbing toolbox - contains plumbing specific tools such as copper pipe cutter, pex cutter, pex crimp tools, assortment of copper and pex fittings and crimp rings, solder & flux (I still have rental properties with all copper). I also carry replacement parts such as thermocouples for water heaters, a couple of different valves and core replacements. several sizes of hose clamps. It also has abrasives (sandpaper, steel wool, nylon scrubbers, etc.). Also included is a small snake and an assortment of rags. I also have clear flip lid totes for holding plumbing fittings, for when I have to change something but this mostly lives on a shelve in my garage.

Electrical toolbox & tool bag - The toolbox mostly contains an assortment of spare switches, plugs, a couple of breakers, and electrical test equipment (meter, NC voltage tester, outlet tester, etc.), boxes of wire nuts, cable clamps, metallic cable clamps, duct seal putty, a small can of PVC cleaner and cement, . The tool bag contains electrical specific tools - wire strippers, linesman pliers, several #2 Robertson screwdrivers, plus a regular assortment (these are duplicates from my general toolbox). One pocket of the tool bag is for short lengths of white, black, red and bare #14 wire that are cut to length for pigtails from off-cuts of other wires.
Network and comm Toolbox - as you would expect, the tools for stripping and terminating Cat 5/6 cables, tools for terminating tombstone jacks, various junction boxes for LV wiring jobs, LV crimp connectors, another crimping tool, an assortment of cover plates for network wiring, etc.
Sprinkler toolbox - spare parts for sprinklers, tools needed for adjusting/replacing sprinkler heads, various pvc fittings, hose clamps, spring clamps, etc.
Power tool toolboxes - I started this recently and not sure I like it, but it works for some things. When I buy a power tool, I like to buy a toolbox for it as well, to keep all the related parts, pieces, and attachments/blades etc. For example, if you buy a router, it comes with a guide, dust chute, wrench, allan key, dust bag, etc. The tool and all the parts for it go in a toolbox so I can keep them together, and then I also include the bits as needed (obviously inside protective cases, not just thrown in). I have a bigger toolbox that I use to transport several (battery) power tools (drill/driver, small impact driver, etc.
I also have: electronics toolbox, bicycle repair toolbox, concrete finishing tools-box for the smaller trowels, locksmith toolbox, etc.

Here's a link to some of my "organization" systems on my garage thread and you can see many of the toolboxes mentioned above.

When I go to do some work at a rental house or wherever, I grab the general toolbox, and the toolbox for whatever other job I may be doing.

 

[Odd-job]

Funny that the OP started off with a 90% small cantilever box concept for automotive and we have gone everywhere including big boxes/carts. Guess 90% coverage can be a wide range depending on the application.

I like some of the ideas above. Really need to get my power tools and accessories under control. Where did the dust collector box for my m18 orbital sander go???

 

[JeepYJ]

Years ago on a Jeep forum a guy performed all the service work in his Jeep- brakes, u-joints, belt replacement, etc. While doing so he made a list of all the tools used for each job and that is what he put in his off-road toolbox. If you’re just going to work on one vehicle that seems to be the way to go. No need to carry a full wrench set if 3 wrenches will do anything you need to do with a wrench. Something to think about as you’re assembling a toolbox for a specific vehicle. And unless you’re carrying a bunch of spare parts with you there’s not much you’re going to be able to fix much without a visit to a parts store, which also sells tools.

 

[theoldwizard1]

• Skip anything 1/2" drive.
• 3/8" standard length ratchet and a 3/8" flex head. Universal. At least 3 different length extension.
• Depending on what kinds of things you work on, you may be NOT need any American sized sockets or wrenches. 1/2" and 9/16" are the most common sizes.
• At least 2 different sized adjustable wrenches.
• Pliers, locking pliers, arc joint pliers, combination wire strippers/crimpers.
• Back saw and blades.
• Box cutter.

When I put together this kind of set 20+ years ago, used Craftsman was cheap, so that is what I bought. Today, I would go with HF.

 

[Mecha]

Look up "junk yard tool kit" on you tube and you'll find a lot as well.

 

[Blind1]

• Skip anything 1/2" drive.
• 3/8" standard length ratchet and a 3/8" flex head. Universal. At least 3 different length extension.
• Depending on what kinds of things you work on, you may be NOT need any American sized sockets or wrenches. 1/2" and 9/16" are the most common sizes.
• At least 2 different sized adjustable wrenches.
• Pliers, locking pliers, arc joint pliers, combination wire strippers/crimpers.
• Back saw and blades.
• Box cutter.

When I put together this kind of set 20+ years ago, used Craftsman was cheap, so that is what I bought. Today, I would go with HF.

5/16’s for hose clamps.

 

[CS454]

My favourite, personally

 

[Robinson1]

Broad question and totally depends on application.

For construction my 90% box would basically be my service truck. A 12 foot enclosed trailer covers 99.9% of the final 10%.

For farming its pretty much a handful of wrenches and a hammer. More involved than that and I'm not willing to fix it in the field. Back at the shop the 90% box would be a 26 inch mechanics box.

For basic maintenance stuff a 16 inch tool bag will cover most things

 

[Drunkonunleaded]

Road/Portable Box for Track and Trail

Background: I've been working out of an old 3-Drawer Craftsman Rally box for the past few years. This is a portable setup that I use for track days or ATV trips. Goal is to perform basic maintenance such as brake jobs, rudimentary alignments, etc. The box presently looks like below: As...

www.garagejournal.com

This is basically v1.0 of my TSTAK roadbox. I've since updated the top box with sockets on Ernst rails and kaizen foam, as well as putting my "big" Kobalt XTR impact into the bottom case along with Kaizen foam (v2.0). I'll try to grab some pictures next time I have the box out to show you what I'm working at.

The v3.0 will be a simple refinement of the original. Namely, cleaning up the foam cutouts to better secure a few of the items and dropping the XTR impact for the new Kobalt mid-torque.

I've added various TSTAK deep tool boxes and totes depending upon my use (one for off-road recovery equipment, another for ATV oils/chemicals, etc.).

For the past year, I've basically worked exclusively out of this box with the exception of impact sockets on some jobs. It covers about 95% of what I have needed to do, including all maintainence (fluids, clutch, etc.) on my ATVs and motocross bikes.

 

[Toolcrib]

My favourite, personally

Those metal totes are nice. They dry out a lot easier than a tool bag!