I’m working on the interior of my “Anarchist’s Tool Chest,” and I’ve decided to slightly rearrange the storage from what’s shown in Christopher Schwarz’s book. Instead of a saw till all along the front wall at the bottom of the chest as Chris suggests, I’m attaching my two panel saws (crosscut and rip) to the underside of the lid. Four backsaws (two dovetail saws, a tenon saw and carcase saw) will go in a shorter saw till at the top left front corner. (I’ll write about the rest of the storage as I get to it.)
Today, I made “keepers” for the panel saws – and it was easy. So easy, in fact, that I had time for a little shop fun when I was done fitting the inserts on which the handles hang.
First, I surfaced my lumber to the exact thickness of the handles (the two were, naturally, different thicknesses). Then, I simply simply ran a pencil around the insides of the handles to trace the shapes onto the stock.
After cutting them out on the band saw, the spindle sander made quick work of removing the saw marks and smoothing the curves of the inserts. I’ll use a rasp, files and sandpaper to ease the top edges for a pleasing look – which to my eye means they’ll mirror the eased edges of the saw grips (plus that will make it easier to slide the handle in place once the inserts are attached to the lid). The inserts will be screwed in place, once I decide what “in place” is.
The toe end of the saw slides into a narrow U-shaped piece, before the handle is slipped over the insert. (No, I didn’t mistakenly attach it to the outside of my chest – that is simply the only clean, flat surface in my shop at home.)
So what keeps the handles from slipping off the inserts when the lid is closed? Toggles – and that was my fun for the day. Go ahead and scoff; they make me smile.
p.s. Before cutting the tiny kitties on the band saw, I made sure the machine was running in tip-top shape (and I used a very narrow blade and lots of caution). The best book I’ve read on band saw tune-up and use is Mark Duginske’s “New Complete Guide to the Band Saw.” Would I have been better off using a scroll saw for these small bits? Possibly…but it’s in our storage room, and I couldn’t get it off the shelf and into the shop by myself.