Grab-and-Go Tool Storage

Build the Bins

• Assemble each of the three bins as shown in the photo below.
• Position the shelves with spacers and tack them in place with a brad nailer. Then add screws for strength.
  • Pro tip: To make assembly faster, we used self-drilling screws, which means you won’t need a pilot hole or a countersink. However, drill a shallow starter hole with a 3/32-in. bit to keep the tip of the screw from wandering off the mark as you start to drive the screw.

Join the Bins

• Line the bins up on a flat surface, then glue and clamp them together.
  • Pro tip: A homemade squaring jig holds the bins square until the back is on.
  • Note: When you join the three bins, you’ll need a work surface that’s absolutely flat; an old flush panel door on sawhorses works perfectly for this.

• Glue and nail on the back.
• Sand the front edges of the bins so they’re flush.
• Glue and nail on the top.

Build the Drawers

• Measure the openings in the bottom of the bins and then downsize the drawer about 1/8 in. in total height and width.
  • Pro tip: Since the drawers don’t have slides, this will give you just the right clearance. Take into account the thickness of the plywood drawer bottom. Sometimes “1/4-in. plywood” is actually 3/16 in. thick.
• Tack the drawers together with nails and glue, then add screws.
  • Pro tip: A squaring jig makes square assembly easy. Drill holes through the back of each drawer to act as a handle.

Build the Lower Shelving Section

• Measure the width of the top assembly and then cut the parts for the lower shelving unit so it’ll be exactly the same width.
  • Note: “Three-quarter-inch” plywood isn’t exactly 3/4 in. thick; it’s actually 23/32 in. That’s why it’s critical to measure. Use the Cutting List as a guide, but measure carefully to be sure.
• Screw the sides to the shelves.
• Install the lower partition (H) halfway between the bottom and middle shelf.
• Cut the 1/2-in. plywood back and check the assembly for square, then glue and nail it to the back of the sides and shelf.
• To reinforce the bottom shelf, rip 3-1/2-in. strips of 3/4-in. plywood (parts P and Q) and glue and nail them to the bottom of the assembly.
• Screw the casters to the strips.

Mount the Slides for the Pullout Table

• Mount the drawer slide that will support the pullout table.
• Lay the upper unit onto its back and glue and screw the outer sides (R) to the bin sides (A).
  • Pro tip: You may need to shim underneath to bring the sides perfectly flush.
• Glue and nail spacers to sides, then add the slides.
  • Note: This is a lot easier to do before you attach the sides to the bins.

Combine the Upper and Lower Units

• Slide the lower unit into the upper unit until it makes contact with the spacers.
• Align the faces of the lower assembly with the outer sides (R) and drive the screws from the inside.
  • Note: You’ll need nine screws per side.
  • Note: At this stage, the project has acquired considerable heft, so get someone to help you tip it upright.

Cover Exposed Plywood Edges

• Glue and nail the edging into place.
  • Pro tip: If the trim is a bit too wide, you can shave it slightly with your table saw.

Assemble the Pullout Table

• Carefully measure the distance between the side spacers.
• Subtract 1 in. from this measurement (1/2-in. clearance for each drawer slide) and build the table to this precise width.
• Cut and screw the drawer faces to the front of the drawers.
  • Note: Be sure you have 1/4-in. clearance between the bottom of the drawer faces and the pullout table.
• Align the edges of the outer drawer faces so they’re even with the table front.
  • Pro tip: To make sure your drawers don’t get trapped inside their openings before you install the fronts, press a strip of masking tape onto the inside front of the drawer and let it hang past the drawer. You can pull on the tape if you accidentally close the drawer.

Trim and Apply a Finish

• Use a wipe-on polyurethane or Watco oil.
• Use a brush to get into tight areas and then a lint-free rag to wipe the finish.
• Let dry and give it a second coat.

Additional Information

• Figure A: Tool Cabinet
• Tool Cabinet Materials List
• Tool Cabinet Cutting List