Gerstner B2116 Oak 1600 Tote Case Instructions

: June 5, 2024
: Gerstner

Table of Contents

Recommended tools
Parts prep before starting the job
Supplemental reference photos
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)
2 Philips screw driver

Gerstner B2116 Oak 1600 Tote Case

*Caution: We use veneer plywood on the top of this case. The plywood gives the box stability through everchanging conditions of humidity. Please note that you must exercise great care when sanding the top surface. The veneer is .010″ thick and excessive sanding on the top can cause a sand‐thru, to the plywood core below the veneer. We suggest you sand the solid wood just enough to meet the surface of the veneer

Recommended tools

2 Philips screw driver
Wood glue
Rubber mallet/Hammer
100 and 150 grit sandpaper
Router with flush cut bit
1/8” round over bit
(2‐3) 18” bar clamps
Electric drill
90 degree square
Your choice of stain/finish
Scale or ruler

Parts prep before starting the job

Make sure you are working on a sturdy flat work surface that will not scratch or dent the parts while handling them. Lightly sand and deburr the part edges while trial fitting them together (dry fit), this will familiarize you with the assembly process.

Locate the box sides as shown. You will notice that each of the sides have been marked with either R (right side) or L (left side). The thinner part, located towards the top of the photo on the next page, are the top pieces. The lower larger section of parts are the main box parts. It is recommended that you maintain right, left, front and back orientation while assembling the box parts together.
Lay the lower box parts on the table as shown. Note that the right side is to the right and the back is to the back and so on. The back is pre-drilled for hinges and the front is pre-drilled on center for the draw latch. The bottom of the box is the light-colored birch plywood. Add glue to the parts for assembly.
Clamp box as shown and wipe off excess glue. Check assembly for squareness with 90-degree square. Allow time for glue to dry before handling and double check to make sure the bottom is flush with the frame components.
Check bottom flushness. This is to make sure the bottom is not in upside down.
Locate, glue and install tray support rails in both the right and left sides. The supports should stay in place after pressing them in. If they move or fall out of the groove a couple pieces of masking tape can be used to hold them in place.
Lay top parts out, glue and clamp in the same way that the bottom section was completed in Step 3. Remove excess glue and check top for square. Make sure top is flush with frame parts and not installed upside down.

More images of this process down below
Next, assemble the tray as shown. The tray bottom is 1/8” birch plywood and is installed in the 1/8” groove cut in the tray parts. Please note the tray bottom will not be flush with the tray frame parts. The plywood bottom is recessed into the tray as shown in the pictures below.
Sand the exterior of the box as desired. USE CAUTION when sanding the top veneer, as it is very thin and can be damaged easily!
Check proper fit of top lid to the box. Sand edge to remove tool marks and uneven gap if present.
Use the supplied hardware to check the top lid fitting. The holes should line up with the hardware if the top was properly fit.
Round over edges with 1/8” router round over bit or hand sanding block to prep the chest for corner hardware.
Check round over with corner hardware. An initial pilot hole has been drilled in the top for the corners. You will have to drill the remaining holes for each of the corners provided. Now is a good time to drill these remaining screw holes.
NOTE: Some hardware may vary slightly from the images shown due to availability.
Check the fit of the tray in the box, it should slide freely front to back. If the fit is too tight you might have to sand a little off of the tray to ensure proper fit.
Stain and finish parts as desired. Gerstner uses 1-2 coats of lacquer sealer and 1-2 coats of lacquer top coat.
Cut and install felt into the box and tray. (We recommend using Gerstner’s Whew Glue!, a protein glue.) Brush the glue onto the surface of the wood receiving the felt. Carefully press into place.
Install hardware onto box as show in the supplemental reference photos below.
Congratulations, you are finished, now sit back and enjoy a lifetime of use.
Check Gerstner & Sons forum for tips, tricks and suggestions about kit chests. When you are finished don’t forget to post a picture of your completed chest on the Gerstner Forum at: http://GerstnerForum.com