Project 1: Making a Tool Tote - Grant Peterson

For this project, I started out by creating a 3D model using Fusion360. I followed the example pretty closely, but I made one modification in the addition of several aligned notches—not with any specific tool in mind, but for a general case of tools that might be longer than the given compartments. After the completion of this model and a translation to dimensioned drawings, I spent some time writing down all the necessary piece dimensions and aligning these pieces on the board in a manner both making efficient use of the material and lining up as many of the same-dimension sides as possible to minimize the difference between pieces that should be the same size. As I continued to cut pieces into the proper shapes and with the proper notches, I made sure to clamp together pieces that should be identical to ensure that, wherever possible, all cut edges and drilled holes lined up symmetrically.

During the assembly stage, I used an edge router to add a slight bevel to all of the exposed edges and sanded each piece to remove rough edges, and once the project was all screwed together I once again sanded all the joins to make them flush. When sanding, I paid extra attention to making the handle as smooth as possible to remove possibility of injury to the user. Finally, I temporarily removed the two main side panels and used the GlowForge to engrave a simple, abstract design on each.

In terms of the final result, I am particularly pleased with how neatly everything came together, and how clean the finished box is. I like how smooth the sides and edges are, as well as the slight bevel to the corners. Though I couldn't get the underside of the handle as smooth as I would have liked, it is certainly the smoothest surface on the whole box, and is quite comfortable to hold. The notches I designed line up nicely, and the construction allows for them without sacrificing any significant amount of overall integrity. The laser engraving is simple, yet makes it unique, along with the notches.

In retrospect, I would have liked to do a little more to finish it off. Though I'm happy with it, I would have liked to have the time to add more small details with the laser engraver and/or apply some sort of clear gloss finish or stain. I also would have liked to figure out some way to fix (or replace) one of the ends, which I accidentally set against the belt sander and shaved down to a darker layer of the plywood.

As for aspects that worked well, it really paid off to measure things multiple times and to leave myself a little wiggle room when I made the initial cuts from the plywood, as this allowed me to trim down any pieces that were slightly larger than they should be and make everything flush. It also paid off to clamp my pieces together to cut the notches and shape the handle edge-pieces, as I feel they would have been much less symmetrical otherwise.