Building a "tool box"...

[steved]

After many years of service, I have came to the conclusion my Knaack box is just not big enough. I believe its a #79, about 24"x24"x60"...construction site toolbox. The box is mounted on a small trailer, I tow it cross country. I believe the frame was a small compressor or generator in a previous life. I placed a set of Dana 60 axle tubes (chopped the center section out) under it for an axle to give me an HD axle (big bearings) with 8 lugs. The deck is about 40"x72", so the box doesn't actually fill it out.

I got a line on some 1/8" and 1/16" aluminum diamond plate (fairly big sheets, as in 30"x60"). Now, I know 1/8" would probably be fine structurally with some bracing, but 1/16" is way to light. I was thinking of building a box to the dimensions of the deck. I was thinking of using 1/2" outdoor plywood to give some rigidity, and then "covering" the wood box with the diamond plate. Probably do either a single hinged lid on one side or two lids hinged in the center (opening towards the ends).

I was figuring this would yield a box around 40" wide x 30" tall x 72" long, significantly larger than what I currently have...and still fairly protected from theft (I never leave the trailer sit anywhere alone, its at most in a hotel parking lot).

Sound like a good idea? Or should I continue to look for a larger Knaack?