Toshio Odate outlined the construction of a simple toolbox in his book, “Japanese Woodworking Tools:Their Tradition, Spirit and Use“. It’s a simple affair nailed together with built-in handles at each end and an ingenious sliding lid. An elegant and inexpensive solution to storing and transporting tools. The design is very scalable and can be adapted as required. It’s also quick and easy to build. Making it an ideal storage solution for both the beginner and experience woodworker. I’ve done a little research trying to discover when this type of toolbox came into use, but have yet to pinpoint any definitive time period. A Lumberjocks member who goes by “mafe” compiled some information and photos of Japanese toolboxes that’s well worth a look. At any rate, this is where I’m headed with my toolbox build.
I started, same as I always do, with a proportional drawing. The drawing shows the basic construction and some suggested proportions for individual parts as they relate to the whole.
A couple of things to note. One is the handle thickness. Odate shows in his book that the handle is 1-1/4″thk, in a subsequent article he calls it out to be 3/4″thk. So it’s not all that critical for the construction. However, it is critical for comfort. The average distance from the tip of a finger to the first knuckle is ~1″. So a handle that is over 1″ thick allows for a full fingertip grip and is far more comfortable. The second point of note is material thickness. It’s very tempting, especially when using surfaced home center lumber, to use the boards at the thickness they are at. Put forth the extra effort and thin down the lid and the bottom panel. Weight is critical when it comes to a toolbox. Thinning these down from 3/4″ to 1/2″ may not seem like a lot, but it will make a big difference in the overall feel of the toolbox.
The only deviation from the general design presented by Odate that I have made, is to install the end pieces in a shallow housing dado. This is not for strength, but to ease the assembly of the box. If you have ever tried to juggle pieces that are only butted together and join them with nails or screws, then you know what a hassle it is. Hopefully the housing dado will be just enough to both index and hold the pieces so I can easily add the required screws.
With my drawing in hand I headed to the shop and started work on the full-scale shop drawing that I will be building this toolbox from. I don’t have a specific set of tools that I’ll be either storing or transporting in this box. As such, my size requirements are fairly minimal. I want the box to be large enough to accommodate a #5 jack and a #4 smoother end-to-end. I also need it to be large enough to hold my ryoba saw. That should give me plenty of space to carry what I need. So I began the full-scale shop drawing by laying out the side elevation of the box. I established the height by simply laying my plane on the drawing and adding a little bit of wiggle room above the highest point of the plane. The length was established in the same manner by laying the #5 and the #4 end-to-end and adding a little breathing room.
Finally I checked the saw against the established lid opening to ensure that it would go into the toolbox without issue.
The width of the box was determined with even less science than the height. The widest board I can get for the bottom at the home center is a 1″x12″. Which will actually yield an 11″ wide board once I dress the edges. So 11″ it is. The remaining elements were established based upon the proportional drawing. Obviously you could take this to the nth degree depending on your needs and carefully size the box to hold a specific set of tools. This is a very scalable design after all. The point being, size the box to fit your needs.
That’s it. The size of my toolbox is established and my next stop will be the home center for some lumber and screws.
Download instructional PDF drawing: Japanese Toolbox