Tool boxes that fit into the back of a pickup truck can be an asset to anyone that uses a truck for work. Metal boxes are expensive and can scratch the bed of the truck. A wooden box can be made to fit any size truck bed. For a box that will be out in the weather, choose pressure-treated lumber and a good quality weather resistant polyurethane varnish. It is also important to use safety hinges. In the hardware store, ask for toy box hinges. They are designed to prevent the lid from dropping suddenly and smashing fingers.
Measure the bed of the pickup. Many tool kits or boxes are placed directly behind the cab, but others are secured near the tailgate for easy access. Make sure wherever you place your box you have a space about 2 feet deep to accommodate the width of the box. Write down the width of the bed where you wish to place the box. Measure the base of the truck bed and the top where the edge of the rails are closest.
Cut both sheets of plywood lengthwise into two equal pieces on the table saw. This creates four 2-by-8 foot pieces. If your truck doesn't have a level 2-foot area, make your box slightly narrower to fit.
Cut one board to fit on the bed of the truck. This will be the bottom of your box. Place the board in the truck bed where the finished box will be.
Place the level on either edge of the bottom. Make sure the level is absolutely vertical without hitting the sides of the truck. Check both sides. When assured the finished box will fit, cut a second piece of wood using the bottom as a pattern. The second piece will become the top.
Place both pieces of wood in the bed of the truck stacked on top of one another. Measure the distance from the wood to the top of the bed walls with the tape measure.
Cut two pieces of wood from the 2-foot-wide planks. It should be the length of the measurement taken in Step 5. These will become the sides of the box. Cut four 2-inch blocks from the 2-by-2 scrap lumber. Cut a small piece of scrap plywood for a marker.
Measure the thickness of both sides. Subtract this number from the total length of the bottom. Cut two pieces this length and the same width as the two sides. These pieces will form the front and back of the box.
Spread epoxy on one of the long sides of the bottom piece. Place the front side of the box in place. Center the piece on the bottom. There will be extra bottom on both sides. This is the room for the side pieces. Spread epoxy on three sides of two of the 2-by-2 blocks. Glue these in place where the front joins the bottom of the box. Make sure the block is flush with the side of the front piece.
Spread epoxy liberally on one of the side edges of the front of the box. Spread glue on the bottom of one of the side pieces. Place this side piece against the glue on the front so the side edges are flush with the front of the box. Press the 2-by-2 block so it is firmly attached to both the front and side piece. Hold for several minutes until the glue begins to set. Repeat with the other side.
Spread epoxy liberally on both edges and the bottom of the back of the box. Slip this piece in place.
Spread glue on the last two 2-by-2 blocks and press them firmly into the back corners of the box. Hold these pieces until the glue begins to set.
Wrap string around the box several times to hold in place. Place several books or some other weight on the corners to press them firmly against the bottom of the box. Allow to cure overnight.
Flip the box upside down. Screw each of the four rubber feet through the bottom of the box just inside of each of the four corners. They should screw directly into the 2-by-2 blocks in the corners. Turn right side up.
Install the safety hinges on the bottom of the last piece of cut wood. Install the other part of the hinges on the back of the box.
Sand the entire box, top, bottom and sides. Paint with the weatherproof polyurethane. Allow to dry.
Screw a latching hasp on the top and front of the box. This will hold the box closed and should leave room for a lock if desired.
Move the finished box into the bed of the truck.
