Troops, Tools - Tomatoe', Tom'atoe, it's still just a box with some attitude.
The first picture shows the 1/2 wide (12mm) plywood I cut out. Eventually, you'll need most of an 8x4 sheet for this project. I'll put the dimensions and cut list at the bottom of the post.
As in all hobby projects, you'll make decisions on the fly which usually adhere to the path of least resistance principal. The use of 45 degree bevel joints is no exception - I'll need to go back and figure a way to strengthen the joints.
The second picture is the initial glue up. Nothing to fancy here other than my Rockler 90 degree clamps. I need to get 2 more! They are wonderful. As state earlier, one can never have too many clamps in a workshop. It the same principal that applies to unpainted minis.
The box is 21 and 5/8's inches long - given the width of the plywood is 0.5 inches that provides an interior with of 20 5/8 inches.
The box is 14.5 inches tall
Why the odd dimensions? - my table saw sled was off a bit as I was cutting the 45 degree bevels. The box is square but I was a little off, hence the "non-multiple of 5" dimensions. In other words, "I screwed up"
We now have a decision - how many and how tall should the drawers be (actually thats the same question). We have a 9 inch space for drawers which means either 2, 4.5 inch high drawers or 3, 3 inch high drawers.
At this point we need to decide what material will the drawers be built of off. I'm going with 1/2 plywood for the sides and 1/4 inch for the bottoms. The interior dimension of each drawer would be:
Interior Length (both options):
Length of 20 5/8 inches less 1 inch for the sides and 1/8 for clearance so 19.5 inches interior length
Interior Width (both options):
Outside width of 14 3/8 inches less 1 inch for the sides and 1/8 for clearance equals 13 1/4 interior width
Interior Height 4.5 inches high:
4.5 inches less 1/4 for the bottom and 1/8 for clearance equals 4 1/8 inch interior height
Interior Height 3.0 inches high:
3.0 inches less 1/4 for the bottom and 1/8 for clearance equals 3 5/8 inch interior height
The interior height is important as the maximum for how tall a mini can be. Most of the tournaments I play in use 28mm troops (Bolt Action or Saga) and both have minis that are taller than 3 inches (tank models for one and troops with flags for the other. If I was just transporting 15mm mini's then the interior height of the 3 inch drawer would be fine.
I'll be going with 2, 4/5 inch drawers for this project.
Given the the interior dimension of a drawers is 19.5 inches by 13.25 inches, that implies a storage capacity of 258 square inches (19.5 x 13.25). If we allocate 1.25 inches per mini that means each drawer can hold 206 28mm figures. A lot of my stuff (ACW, Napoleonics) are based on 4 figures per 40mm square base so I could fit 100 bases (at 2.5 square inches per base).
Dimensions & cut list for the outer case
1, 21 5/8 x 14.5 inch back panel
2, 14 3/8 x 14.5 inch side panels
1, 21 5/8 by 4.5 inch front top runner
1, 21 5/8 x 1 inch front bottom runner
3 21 1/8 x 13 7/8 bottom panels
Rough Project Plan (I doubt I'll actually stick with these steps)
- Installing the bottom panels with rabbet joints
- Drawers construction
- Installing the lid
- Reinforcing the Joints
- Wood finishing and clean up
- Hardware and other bling
I am "stealing" these plans from a Jimmy Diresta video, which is referenced below - Mr Diresta is a master craftsman and makes interesting videos. I suggest you take a look to see how to build the case correctly rather than my haphazard way.