Build a Classic Wooden Toolbox

With the dovetails completed, next we'll need to cut the dadoes to hold the bottom of the toolbox. Since these dadoes will not extend the entire length of the sides and ends of the toolbox, we'll use a straight-cutting bit in a router to cut the dadoes.

Because the 1/2" plywood is actually 15/32" thick, using a 1/2" straight-cutting bit will create a dado that is a bit too wide, making the bottom fit sloppily. Therefore, we'll use a 1/4" straight-cutting bit and make two passes.

Install your fixed base router into your router table with the 1/4" bit set to a height of 3/8" above the table.

Set the fence on the router table 3/8" away from the bit. On the fence of your router table, make a mark 1/2" on each side of the bit. These will be start and stop points for the piece as it is being routed. By employing this extra step, you'll avoid damaging the dovetails by not cutting the dado all the way to the ends of each of the four pieces.

Wearing your safety glasses and hearing protection, start up your router. Place the inside of the stock (that you marked in a previous step) facing down toward the table and just above the router bit. Maneuver the piece so that the end of the piece is at the far mark on the fence, and ease the stock down onto the bit, holding it tight against the fence. Push the stock forward until you reach the back mark with the trailing edge of the stock, and then lift the piece off of the bit. Repeat with the other three pieces.

Adjust your fence another 7/32" away from the bit. This should result in a 15/32" wide dado after the four sides have been run through the router table in the same method as before. However, it would be wise to cut it a bit shy and test with the piece of plywood for the bottom, as the plywood's thickness may be slightly out of the norm. Once the width is set, cut all four dadoes to proper width.