Tool Box Assembly Instructions
Remove the plastic coating and deburr the edges of all the parts
Cleco the ends to the outside of the tool box body with a Cleco in every other hole.
Match Drill the open holes with a #40 drill. Move the clecos to the open holes and drill the rest. Deburr both sides of all the drilled holes.
Mark one end left and one end right. Dimple the end holes in the body and the ends making sure to dimple the outside of Left and Right ends.
Rivet the ends of the body with AN426AD3-3.5 flush rivets. (3/32" flat head)
Cleco the front stiffener to the body with the bend toward the inside of the box. Reverse the hinge segments and determine the hinge length. The lid segment of the hinge fits inside of the lid flange. The hinge segment for the lid will have eyelets facing down and the segment for the body will have the eyelets facing out from the body. Cut the hinge to length. Leave the pin long for now. Clamp the body segment of the hinge to the body with the eyelets even with the top edge of the box. Remove the front stiffener. Math drill the hinge and body with a #40 drill and Cleco as you move along.
Replace the front stiffener with clecos. Position the lid and hinge in place and insert the hinge pin. Mark the position of the hinge n the tip by drawing a line on the exposed eyelet with a Sharpie pen. Remove the hinge pin and the lid and clamp the top hinge in place. Match drill the hinge to the lid. Deburr all the holes in the lid and hinges. Dimple the body, the lid and the hinge segments making sure to dimple the proper side of the hinges. Rivet the hinges of the body and the lid with AN426-AD3-3.5 flush rivets.
Now match drill the front stiffener with a #39 drill. Deburr all the holes and rivet the stiffener to the body with AN470AD4-4 rivets (1/8" flat head)
After drilling with a #30 drill and deburring the holes, rivet the bottom latch half to the body with AN426AD4-4 flush rivets. (1/8" flat head)
Put the top on the body and insert the hinge pin. Put the bottom latch half in the closed position and hold the hook portion up against the wire bail. Mark the hole position and drill the #30 holes for AN470AD4-4 universal rivets. Rivet the hook into place.
Bend the handle from the .090" hinge pin wire supplied using the drawing as a guide. You may heat the handle to make it easier to bend.
Place the handle and handle clips on the box lid in position. Mark one hole on each clip. Drill and Cleco one hole in the clip, then the other side. Deburr the holes. With the handle in place, and a Cleco in one hole, rivet the other side with an AN470AD4-4 universal rivet. Rivet the other side of the handle clip.
Cut the hinge pin 3/16" shorter than the total length of the hinege and slightly crimp the end hinge eyelets to retain the pin.
Stand back and admire your work