Savage Toolbox Replica

[ebswift]

Hey all, I just started my first replica build. I am soon to start engineering study and I actually work in an engineering school, plus I need to learn how to draw, so I thought what more fitting thing to have than a toolbox from one of our favourite engineers.

First things first was to find all the references with measurements (lots of googling). Next I found some drawings posted on these forums and started working from there. To proceed I had to learn how to draw from scratch, this was challenging... Once I replicated some of the drawings I went back and checked the references. Some things didn't match up, like number of tabs for the lid, number of rivets, some of the overall measurements and the general bracket setup and mitre joints.

I figured at that point that I'm either replicating this box or making my own. If I was going to make my own it would be fully customised for me, but that's not what this little project is about. It's a Savage Toolbox, not an ebswift toolbox. So this led me down the path of re-doing everything humanly possible to spec, not OCD-like, but visually-close-enough-like. All the files are saved in a Google Drive folder so they're backed up on the cloud. I can retrieve them from work or home and a computer crash won't result in their demise.

Next up was sourcing parts. Latches came from part numbers on this forum (had to import from US), hinges came from a local supplier here in oz from ebay. I'm still working on getting handles, they're important but tricky in oz... The design was built around bits I could actually get. For the handles I might end up just going for generic plastic ones designed for other things from what I can source in oz. The other possibility is Vinnies, finding old leather suitcases or something.

So using Autodesk Inventor, learning from scratch, I came up with the 3D design, replicated the hinges from their measurements, and got it to a point of being able to animate the lid design to check everything. I did a short video of that here:

From the Inventor drawings, I created dwg files and approached two companies here in oz for cutting the sheets. Neither got back to me. So, I contacted a Chinese company and they were happy to work with me. Sent the drawings, got quotes, and a week and a half later I have the laser cut sheets, holes and all.



They turned out rather nice I think, and they show that my drawings at least translate into reality.

A friend has some laser cutting gear (not for metal), so he will help make Savage Toolbox decals for the lids, as per the reference photos. The gear won't work on the 6061 aluminium from my research (it can really only etch powder coat). I'll get some help from a good bloke in our workshop at work to get me going on doing mitre cuts in the angles and start riveting (hopefully this week).

So, just gotta source handles, complete the build with the bits I have, then add the handles & latches as they come through the mail. I will follow this through to completion, I don't really want to go for First Order Retrievability, I'm not really specialised to need/want that at this point in time. Likewise, the scissor lifts would really be overkill for my needs, I just want to complete a Savage Toolbox to satisfy my own challenge of learning to draw, dealing with manufacturers to cut my drawings and end up with a damn cool toolbox!

Proof will be in the pudding .

 

[ebswift]

Just a quick update, I haven't had time to begin the brackets and other parts of the construction, but my friend was able to cut the decals for me. I'll warm them up and glue them onto the lid. Getting them aligned might be tricky once glue is applied.

The photo is obviously just a rough layout.

 

[ebswift]

So little time to work, but some more pics of the construction. Doing all the angles with our band saw, going for the double mitres as per the original box rather than square cuts we see in many of the already done replicas, we'll see if everything fits soon. Just the two long side brackets to make now before drilling.

 

[ebswift]

Starting to take shape, lid 1 went together pretty well. Unexpectedly, the curve fit was easiest, the planned holes lined up. The angles took more work, some individual shaping required for the top of the curve, and getting them lined up close enough to the holes. I think this lid does some justice to the original design.

 

[Mr.Spider]

It's beautiful ! fantastic work. Adam would be proud

 

[ebswift]

Thanks mate . It's amazing how much can go into making one little box!

 

[ebswift]

Well, more progress, all I can say is I bow to our master who did TWO in 24 hours (!). Not sure if the scissor lifts were in the same timeframe, but I just can't imagine how, not that I wouldn't believe Adam.

I couldn't access our nice band saw over the weekend, nor did I have access to some nicer angle material, so I dragged out my trusty cutoff saw and some recycled angle that already had the odd hole here and there. My mate in the workshop was expecting me to rock up to complete cutting next week, so I got ahead a little bit.

Here's my cutoff saw doing the angle mitres, it's not really recommended, but there's no way I could do a straight line with the hacksaw and no helping jig:

The double-mitres came together surprisingly well. The actual riveting of this contraption was pretty stressful, riveting pieces into place, drilling out holes, drilling out the rivets so I could get to other parts and repeating. This was due to having holes pre-done in the sheet metal, but not in the angles. Because I was using a gnarly cutoff saw I didn't trust my drawings to go centre-punching holes from my design, there was just too much give or take on every angle part. The sheet was precise, being done with laser. Whilst everything ended up pretty ugly while working, the rivets hid away many sins.

Finally, here's the WIP, not done yet. The lids do fold together somewhat forcefully, so I think I need to shave off some of the material that is interfering, or option 2, drill out some rivets, and re-drill the holes with the lids positioned, I need to think about that but I'm into the evening now:



And no, it's not an advertisement for AEG, it had the heft to pull the lids down, it does show that they will fit. When the latches come through the mail, they will obviously draw the lids together, BUT, as they are, they have to be coaxed into position and spring back out. I doubt if the material/rivets will conform anytime soon unless I had a machine to open/close some thousands of times.

I nearly didn't get the lids on, I didn't buy enough 4mm rivets which was a downer. But as luck has it, in the dark corner of a box in my shed I found a yellowed box of new 4mm rivets, that obviously about 10 years ago I must have figured I will need for this project .

Work to finish is getting the lids conforming better, fitting latches after they come through the mail, and applying decals that I posted earlier. Don't know when the latches are coming through, they're on back order, but I will work on the lid fit in the meantime.

 

[ebswift]

Another update, I was upset about the clearance issues with the lids. I shaved off some slight overbite which didn't make much difference. Then I gave it a nice massage. That did the trick. I'll massage it some more to make a loose fit (very doable it seems), at this point it still grabs a smidgen. While that will never be an issue with the latches, closing the lids can force one end out or in due to its ability to twist a bit at the end. The way it was I didn't want to show my mate in the workshop .

Edit, proof:

 

[ebswift]

Okay, decals done, both lids. Ye gads, that took some work. Not perfect, but neither was the reference.




And the reference...

 

[jarroth]

perfectly aligned and spaced rivets make it look too factory made. but otherwise, great work!

 

[Contec]

Let call Adam himself to this thread. Hey asavage check this out!

 

[ebswift]

Thanks for the comments guys. The latches arrived today and I learned something new, they do not come with the paired grabber. So, off down to the workshop and made a quick fabrication. Latches are now done, last thing to do is the cables to hold the lids when open.

 

[asavage]

That's gorgeous! Wow. Nicely done. Really really lovely. I hope it serves you as well as it served me. Are you going to build the scissor lift?

 

[asavage]

I'll have to show pix of the interior tool sorters. Made in minutes from weld-on glued together acrylic cut and slotted on the table saw.

 

[ebswift]

Hey, thanks Adam, really appreciate having your comment! This box will be in daily use, make no mistake. As for the scissor lift, I have no immediate plan to make it, but next time I get the make itch...

Cheers!

 

[ebswift]

I learned a new trick tonight, I used a clear "SikaBond" spray adhesive to put the lettering on the lids. The letters did their best to try and straighten out overnight which is a bit problematic, they will fall off if they do that. What I found is that by re-applying the heat gun to the lifting letters, after one night, either the SikaBond is still tacky, maybe it starts working again under heat too (not sure) - either way, the lettering was able to be re-formed and tacked down again. This isn't the kind of thing you would want to leave too long to do, dust and grit will accumulate and you won't be able to rescue your project.

Looking forward to those pix Adam! Also looking forward to that sweet poster from Tested that will be a nice complement to my build.

 

[asavage]

The poster will include a complete list of every tool I had in those boxes. As well as a reasonable view of the sorters in each.

 

[dhunpael]

asavage,

I subbed to tested.com specially for that poster =D
Now i'm bugging them with emails to get the older poster as well =D

Also: very nice build

 

[ebswift]

asavage, yep, the sorters are half the trick to this box. When I start to specialise in the tools that I go to, I'll start to develop some sorters. ATM it's some of the usual suspects, screw drivers & callipers. I'm also carrying my lab power supply, some Raspberry Pi's and a breadboard with STM32 stuff happening, so there's no particular layout for sorters that works for me right now. Your setup was a specialised kit and would have been awesome for the job at hand with scissor lifts & sorters.

My request is a video segment on these boxes even if the specialised tools have been since organised into other storage systems .