Custom Socket Tray

[altec]

After laying out the top of my Dayton box for sockets, I ran into two issues. I had a blank space that no normal options would fit in, and I don't have a spot for singles, and special sockets. Stuff like spark plug sockets, and O2 sockets... So I decided to take a sheet of 1/8" Delrin I had, and use some $0.99 HF rails and make something to fit. :up:


I started by taking some measurements of the space. I took the measurement I got, and undersized everything by roughly a 1/8" to allow room to get it in, and out.

The spot...
http://i13.photobucket.com/albums/a269/Mrjunior/11/IMAG0622.jpg

The supplies...
http://i13.photobucket.com/albums/a269/Mrjunior/11/IMAG0623.jpg

I started by taking a cheap square, and using some vice grips clamped it down where it roughly looked right. Then used a tape to get it perfect.

I then took a carpet knife, and scored the ever living hell out of the Delrin. Until I was roughly half way through the material.

After this I took the clamps off, and put the Delrin in the vice clamping it along the seem. With a sharp push, the score broke perfectly!

http://i13.photobucket.com/albums/a269/Mrjunior/11/IMAG0624.jpg

Ta-Da!
http://i13.photobucket.com/albums/a269/Mrjunior/11/IMAG0625.jpg

Next step was to cut the short side. I was having trouble scoring it, so I took the light score I had, and using a fine tooth hack saw to it. That glided through the Delrin like butter!

The final piece after hitting it with a file.
http://i13.photobucket.com/albums/a269/Mrjunior/11/IMAG0626.jpg

It fits!
http://i13.photobucket.com/albums/a269/Mrjunior/11/IMAG0627.jpg

The hard part was the rails themselves... After figuring out the length I want, I marked, and cut one of the rails. Then I laid it on top of the other half I had left lining up the end holes, and marked it. Making sure to compensate for where the mark was compared to the first mark I did... To help imagine, I basically cut a 1" out of the middle when all was said, and done...

Then I had to drill the two holes to mirror the original end holes. To do this, I stacked the rails on top of each other, but turned 180*. So the top ones hole, is overlapping the side of the bottom one without a hole. If that makes sense... Then I took the vice grips, and clamped them together. After this, it was a simple matter of drilling, and cleaning the holes.

Then I laid the rails on the Delrin, and after position them where I wanted, I drilled the holes.

Drilling...
http://i13.photobucket.com/albums/a269/Mrjunior/11/IMAG0628.jpg

The final step was to drill and tap the holes to bolt the rails down. Not sure if 10-32 screws will do a great job of holding in 1/8" of Delrin, but we are gonna find out!

http://i13.photobucket.com/albums/a269/Mrjunior/11/IMAG0631.jpg

How does it fit? Well, I could feel is displacing air when I sat it down in the spot! thumbsup2

http://i13.photobucket.com/albums/a269/Mrjunior/11/IMAG0633.jpg

Hopefully this has inspired at least one person, and showed that organizing doesn't have to be expensive. :)

[msmrx57]

Hopefully this has inspired at least one person, and showed that organizing doesn't have to be expensive. :)


Well, you've definitely given me food for thought to address some issues with my tool box. :up:

[x88x]

Looks great. :up: I didn't know about those cheap socket rails from HF...I might have to get some of those...

[xr4man]

this has inspired me. good job!

[altec]

Thanks!


Looks great. :up: I didn't know about those cheap socket rails from HF...I might have to get some of those...

At Glen Burnie HF they are on the right side of the socket isle on a shelf about half way up. All sizes $0.99. They are more flimsy then some of the higher end ones I have, but for basic stuff they are fine, and even getting them for the clips is worth it... I have a bunch of rails that the clips have worn out on.

They also have some Hansen knock off trays, which aren't bad. Although the Metric set skips a size...

Since I'm reorganizing my box, I've been hunting around for different options. I've settled on Hansen trays for Metric, Kobalt trays for SAE, and a VIM 444 tray for the impact, 1/2 chrome, and bit sockets.

http://www.tooltopia.com/vim-v444.aspx

Here is how it currently sits. Still need to get the 1/4 Hansen, and the VIM tray. The Gearwrench driver hasn't found a home yet...

http://i13.photobucket.com/albums/a269/Mrjunior/11/IMAG0635.jpg

[xr4man]

you're in maryland too????

[altec]

Yep, so is 88. I'm in South County. South of Edgewater.