Stanley Sorting Box Tray System

This is a set of parts for mounting a Stanley brand sorting box (small or large) to a drawer slide making them much more convenient to use. The goal is to have the cost per drawer, including the slides, to be less than the cost of the box.

Features

• Sorting boxes are removable, just pick them up by the handle
• The sorting box handle is the drawer pull, no extra hardware to buy
• Sorting box lids can be opened while in the drawer. Accessing your parts super is now convenient!
• Sorting boxes are easy to re-insert and sit securely without moving around. “Fingers” slot into the box holding it in place.
• A laser cut tray connects the two drawer slides so they always stay aligned
  • The tray doubles as extra storage for unsorted bulk items
  • The tray parts can be cut on hobby sized lasers
• Low cost: drawer slides + printed parts + plywood + screws cost less than the sorting box. Under $20 a drawer is achievable.
• Optimized structure: the printed parts are designed to have a minimum of infill volume. Support ribs and fillets give the parts their strength.

Tools Required

• 3D Printer that can fit a 245mm long object (Such as Prusa MK2/3/4)
• Laser cutter for 3mm plywood

Sorting Boxes

• 25-Compartment Shallow Organizer
• Deep Pro Professional 8-Compartment Organizer

These are a much lower cost alternative to the Sortimo boxes.

Drawer Slides

To hit the cost target a good and cheap drawer slide was the first design decision. This is an economy slide with a detent when closed to prevent heavy drawers from sliding open. 

• KV DuriSlide 4500 100 lb Full Extension Slide
  • Model No:  KVDUR45 B18
  • 17 ¾" length
  • Spec Sheet

The plastic parts were designed around the hole spacing and length of this slide. You might be able to substitute another drawer slide of similar length (17 ¾ inches), but you need to verify that the mounting hole locations are compatible. With a volume discount you should be able to get them for less than $8 per pair. 

Printing Suggestions

• PETG strongly suggested
• 3 perimeters with a 0.4mm nozzle or 2 with a 0.6mm nozzle

PETG provides good self tapping threads for the screws, eliminating the need for melt-in inserts. PETG's flexibility is also good for the interface with the laser cut box.

Assembly Instructions

1. Build the laser cut box and allow the glue to dry. Assemble one set of parts:
   
2. Slide a Back support rail onto one side of the laser cut box with the “skeletal” part facing outward. No glue is required, the parts should be a snug fit:
   
3. Next attach a drawer slide to the Back support rails with 2 screws. Leave screws slightly loose.
   
4. Fit the Front support rail into the dovetail of the Back support rail. Make sure the “fingers” are facing upwards and the “skeletal” features are facing outwards. Attach with 2 more screws and leave then slightly loose
   
5. Tighten all screws, the parts should self align.
6. Repeat for the other side.

OnShape Plans & Cabinet Info

Sorting Box Cabinet

The CAD also contains plans for the cabinet, laser cut templates for drilling mounting holes for the drawer slides and a router template for cutting the rounded corners. I expect most people will want to design and build their own cabinet, this can just be a starting point for measurements etc.

The critical cabinet internal dimensions are:

• 452mm wide
• Each drawer needs 460mm of depth minimum, this cabinet uses 472mm of depth so the handles can be set back.
• Each drawer is 54mm tall. You need to add an additional clearance of 4mm between the drawers. So each drawer has a space claim of at least 58mm. If your items are very heavy they might sag more and require additional clearance. I've seen other plans use ¼" / 6mm.

Let me know if you make one! 😀