I didn't want to hijack someone else's thread on their project, so here's a toolbox I made recently, my contribution to Sean's call for project posts. This was all with hand tools, requiring a lot of the techniques we discuss here. Fully loaded, it came to 62lbs., which is just too much to carry up and down the basement stairs without hurting myself, so I now I just use it for saws and long items.

The full build is documented at www.closegrain.com/2010/09/portable-toolboxes.html, showing all the invididual operations with the various tools (and a little antique tool tuning).