JAPANESE TOOLBOX

PLANS - DIMENSIONS - DETAILS - NOTES

CONTENT
2. CONTENT
3. ASSEMBLY VIEWS
4. OVERALL DIMENSIONS
5. FRAME ASSEMBLY
6. BOTTOM AND HANDLES
7. LID ASSEMBLY OVERALL DIMENSIONS
8. WEDGE SYSTEM DETAILS
9. LID AND WEDGE ASSEMBLY
10. PLUG HOLES AND BOTTOM PLATES

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 Japanese Toolbox
ADRIAN PREDA WOODWORKS ASSEMBLY VIEWS
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 1 in [292mm]
112
20 in [508mm]
3 in [19mm]
4

23
8 in [60mm]
1 in [158.5mm]
64 5 in [127mm] 65
8 in [167.5mm]

1 1
2 in [12.5mm] 2 in [12.5mm]

23
8 in [60mm] 9 in [229mm] 23
8 in [60mm]
INTERNAL AVAILABLE SPACE

1
2 in [12.5mm]
11 in [119mm]
416

10 in [254mm]

1 in [445mm]
172

(and 9 in [229mm] width)

1 in [63mm]
22 13
8 in [35mm]
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 A

3 * note 2
32 in [2mm]
* note 1 A
B
1
2 in [12.5mm]
20 in [508mm]
3 in [19mm]
4
A Notes:
1. Small groove, depth not critical, just to
1 in [25mm] guide better the pieces and hide any
imperfections when cutting the tenon side.
2. Proud tenons. Dimensions are based for a
5 in [127mm] 2X 1 1
8 in [3mm] proud with a circa 16 in [1.5mm]
chamfer. You can modify this or even make
them flush. Also by adding wedges, but the
1 in [25mm] tenons are not so long, there is a risk of
breaking them.
1 1
2 in [12.5mm] 2 in [12.5mm]
1
2 in [12.5mm]
1 in [260mm]
B
104
3 in [233mm]
916

1
~ 16 in [1.5mm] chamfer
9
5 in [127mm] 2X 16 in [13.5mm]

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1 in [25mm] 1
~ 16 in [1.5mm] chamfer FRAME ASSEMBLY
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 C
* note 5 * note 4

small radius with sandpaper

1
~ 16 in [1.5mm] chamfer

C 1
~ 16 in [1.5mm] chamfer

* note 3
1
2 in [12.5mm]
20 in [508mm]
Notes:
1. Cut the width about 81 in [3mm] more on each
side and then plane it flush after assembly.
2. When glueing and clamping the bottom there is
a risk to slip away. I usually use two hidden thin
nails placed in diagonal on the sides frame.
10 in [254mm] Hammer the nails about 3-6mm then cut the "hats"
with a plier so just the sharp tips will remain above.
* note 1 * note 2
Before adding the glue, fix precisely the bottom
over the frame in order for those remaing sharp
tips of the nails to make a mark/hole. Add the glue,
then fit the bottom based on these marks. This way
you prevent any slipping due to clamping pressure.
3. This should be chamfered after planing it flush.
4. Cut the handle a hair longer, then adjust it for
3 in [19mm] nice tight fit with no gaps.
4 9 in [229mm] 5. Plane the edges flush.
* note 4

23
8 in [60mm] 2X 3 in [10mm]
8

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1 in [25mm] 1 in [25mm]
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 9 in [40mm]
116 9 in [229mm]

1 in [292mm] 10 in [254mm]
112

1 in [31mm]
14

9 in [39mm] 3 in [10mm]
116 8
13
8 in [35mm] 23
8 in [60mm]
23
8 in [60mm]
5
16 in [8mm]
3 in [19mm]
4
25
8 in [66.5mm]
5 3 in [19mm]
16 in [9mm] 1 in [410mm] 4
168

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LID ASSEMBLY
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OVERALL DIMENSIONS 7/10
 15 in [23mm] 9 in [40mm]
16 116 23
8 in [60mm]

2 6 5

80°
* note 3

*note 2 * note 1

25
8 in [66.5mm]

2 5
Prepare part (2). You can size it to exact dimensions on this stage or leave it more longer and wider, as
described on the next page.
Make a 80°(10°) taper on one long edge of part (2).

1 in [292mm]
112 For part (5) and (6) start with a single piece, at 11 21 in [292mm] long and about 3 in [75mm] wide minimum.
Mark a line at 2° in order to split the piece aproximately in half.
Make a cut on this line by tilting also the saw or blade 10° on the left. See note 1.
If you did the cut with a handsaw clean the edges with a plane making sure you have the same angle on
*note 3
both pieces, (5) and (6).

Taper at 10° the other side of the wedge (6), note 2, in order to match with the angle of part (2).

92° Adjust the widths of parts (5) and (6) aproximately as per drawing. When you attach them side by side they
must have the same overall width, see note 3 on the drawing.

6 Chamfer and round the ends of the wedge (6). Leave part (5) longer, as it will be trimmed after assembly.

The wedge (6) is better to leave it longer because of the wood movement. Very small changes will make the
wedge either not to go all though or to be stucked before the end if cut exactly to dimensions.

1 in [32mm]
14 1 in [32mm]
14
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 Prepare the parts (1) and (2). There are two options here. (a) In order to obtain the inner chamfers,
2 1 see note 1, the parts must be cut exactly to size then fitted precisely into position (you can do this with
the nails trick presented on the previous pages, or make use of the square plugs holes and add
screws to fit them). (b) If you find this difficult, you can leave them about 81 in [3mm] longer and wider,
then flush trim them after glueing.

1
Prepare the lid, part (3). Make this about 16 in [1.5mm] narrower (check by fitting it to the box) in order
10 in [254mm]
to allow for wood movement during seasonal humidity changes. Also make it about 41 - 38 in [5-10mm]
longer than the dimension shown (if you made the box so far at the given dimensions, probably this
* note 1 will not be necesary, but for safety is better to have some material to cut off later).
3 in [10mm]
Prepare part (4) leaving it about 38 in [10mm] longer. 8

Glue part (4) to the lid (3) at 38 in [10mm] from the edge
4

°
23
8 in [60mm] 23 making sure it is squared. It is best to add glue just in * note 2
8 in [60mm] the middle, no more than 2-3 in [50-75mm] to allow the 3 90°

°
80° wood movement on the sides. Or you can add two dowels
on the inside, at the ends of this lenght (note 2).
3 in [19mm]
4
3 3 23
8 in [60mm]
Position the assembly of part (4) and lid (3) inside the box,
1 in [410mm] 5
168 16 in [8mm] then fit and glue/screw part (1) so this will be at 2 38 in [60mm]
from the box outer edge and the handle (4) is alligned with 4
part (1).

Now that these parts are fitted in place position the lid (3) with
its attched handle (4) inside (you can add some blocks under, 5
16 in [9mm]
1
as it will fall on one side), then place and hold/clamp part (1)
9 in [229mm] aproximately where it should be glued (at 2 38 in [60mm]) and
simulate how the lid will be opened by moving towards part (2)
then lifting it. This will give you an idea how much it will be
5
shorthened. You should leave about 16 in [9mm] inside.

Position parts (5), (6) and (2) in place, making sure (2) is set at
2
2 38 in [60mm] from the edge. Fit wedge (6) and part (5) in the
10 in [254mm] 3 in [19mm] desired position, see drawing on previous page for reference,
4
4 then mark where (5) is sitted. Take them out now and glue part
13
8 in [35mm] (5) to the lid (3) based on the markings. marks
Once these are glued, position again the lid assembly in place,
1 in [32mm]
14 parts (3), (4) and (5), position the wedge (6) moving it back and
10 in [254mm]
5 forward so part (2) will find its position at 2 38 in [60mm] from the
9 in [40mm]
116 outer edge, make sure wedge (6) will not move (clamp), then

1in
80° 6
glue part (2).
Trim parts (4) and (5) flushed with the box 2 6 5 4 1
112 side. Same with parts (1) and (2) if were
2°
3 in [29.5mm] left larger. Then chamfer the edges. Japanese Toolbox
116
9 in [39.5mm]
116 ADRIAN PREDA WOODWORKS LID AND WEDGE ASSEMBLY
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 5 5
3 16 in [85mm] 3 16 in [85mm]

1 in [25mm]

1
2 in [12.5mm]

3 in [9mm] 1
8 16 in [1.5mm] 1 3 in [9mm]
1 8 in [3mm] 8
4 in [6mm]
1
2 in [12.5mm]

6X

15
8 in [40mm]

77
8 in [200mm]
1/8-1/4 in [3-6mm] thick]

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15 in [380mm]
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