This project was built and designed by Chris from B&O Craftsman. It’s a compact and elegant storage box made specifically for chisels, crafted from leftover Baltic birch plywood.
Designed for utility and efficiency, this project shows how a bit of planning and precise joinery can turn scrap material into a refined storage solution. Whether for organizing hand tools or just making use of shop offcuts, this build is practical, satisfying, and highly repeatable.
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Planning the Layout
The process began by arranging the chisels on a work surface to figure out the ideal size and spacing. Chris used the top of his table saw to lay everything out, giving him a good visual reference for proportions and fit.
He originally planned a slightly wider design but adjusted the width to keep the box compact. The result is a tight, efficient layout that holds the tools securely without wasted space.
Design and Dimensions
Chris drafted a quick drawing to guide the build and establish measurements. This reference made it easier to stay consistent through each stage of cutting and assembly.
The box sides and bottom were made from ½-inch Baltic birch plywood. It’s a great material for small boxes—stable, clean-edged, and readily available in scraps from previous projects.
Joinery Choices for Strength and Fit
Rabbet joints were cut along the edges of the side panels so they would sit cleanly against the bottom panel. Dado cuts were added to the sides to house the sliding cover, allowing the lid to sit flush and function smoothly.
Once the joinery was complete, Chris performed a dry fit to check for gaps and misalignments. Everything came together snugly, thanks in part to careful measuring and clean miter cuts made with a sled on the table saw.
Clean Miters and Precise Assembly
Miter joints were used to connect the box corners, chosen for their clean, seamless look. Using a miter sled ensured that each corner was accurate and square, which helped the overall box come together without adjustment later.
The pieces were glued up and left to dry overnight. This allowed the joints to cure completely, avoiding shifting or misalignment that can happen with rushed assembly.
Adding a Functional Drawer Pull
For the lid pull, Chris used a piece of solid hardwood to add both visual contrast and durability. The shape was simple and matched the overall clean design of the box.
It was glued securely in place and sized to provide a comfortable grip without overwhelming the sleek proportions of the piece. This small detail helped turn a purely functional item into something more refined.
Smoothing and Finishing
Once the glue had dried, the box was sanded thoroughly on all sides. Chris focused on softening any sharp edges and leveling the joints for a smooth, seamless feel.
To finish it off, he applied a few coats of spray lacquer. This not only brought out the subtle grain of the birch plywood but also offered protection from handling, dust, and workshop grime.
Practical and Purposeful
The finished box is a great example of practical woodworking with a clean design. The chisels sit snugly inside, the lid operates smoothly, and the overall size makes it easy to store on a shelf or in a tool cabinet.
It’s a modest project in terms of materials, but one that showcases solid fundamentals like layout, joinery, and clean finishing. For anyone looking to organize hand tools or explore small box construction, this is a great place to start.
Please support Chris by visiting his website here: https://bo-craftsman-shop.creator-spring.com/