Part 3: Filling the guts of your Dutch Tool Chest-Lid panel saw fixtures


I created two fixtures similar to Christopher Schwarz in order to dock two panel saws (rip and XC) to the inside lid surface. After trial and error, I came up with these fixture dimensions:

P21-Dutch-Tool-Chest-Panel-Saw-Fixture-Dimensions

The rip saw’s handle faces to the left while the XC saw’s handle is located to the right-hand side of the lid. When the lid is open, the teeth face upward. Since each saw is wider toward the handle than the toe, the groove to house this portion of them is longer. I laid the saws one over another and determined a rough placement of the fixtures.

P22-Dutch-Tool-Chest-Panel-Saw-Fixture-Placement

This helped me to then measure the width of the corresponding fixture groove, from the saw spine to the tip of the teeth. With this done, I laid out the fixtures…

P18-Dutch-Tool-Chest-Panel-Saw-Fixture-Laying-Out

…and cut the stopped grooves at the router table.

P20-Dutch-Tool-Chest-Panel-Saw-Fixture-Routed-Slots-And-Shaped

The longer grooves barely had 1/8” between them and the ends of the fixture. So to keep them from breaking, I reinforced them with plywood pieces to prevent breakage. I subsequently revised the fixture dimensions you see posted above.

Note the “Base Line” in the above photograph. The spines of both saws will rest in the same plane with the lid open.

Next, I cut the long notch at each fixture end, then drilled a hole (about 5/8” in from the end) and countersunk it to accommodate the mounting screws.

The 4” placement of the fixtures from the front edge of the top of the lid allowed enough clearance between the fixtures/saws and fully-loaded tool rack for the lid to properly close.

With the lid done, I turned my attention to completing the fixtures for the top section of the chest. And that’s the subject of the next post.

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© 2014, Brad Chittim, all rights reserved.

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About The Write Biz

By day, I'm a mild-mannered copywriter who harnesses frontal-lobe creativity (right brain) to help B2B marketers generate leads and sales. By night I pick up hand tools to create wooden masterpieces...and give my black lab Bella the "red dot" laser to chase after.
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