Simple Lightweight Hinged Storage Box

[Ken Kortch]

I have several lengths of aluminum track saw that I would like to store and protect. I'd like to build a lightweight storage box for them. It would need to be 5' long, about 1' wide, and 8" tall - maybe less. I'd also like to build a similar box to hold the saw and other supplies. 

I picture a 5-sided plywood box with a simple plywood lid connected by hinges, held shut with some kind of latch, and some kind of a handle to move it around. I'm thinking simple and utilitarian, not fancy at all.

I'm just not sure how to build something like that. It seems like using the Kreg Jig would make a very strong box, but I'm wondering if use of thinner plywood needed for low weight would allow strong joints.

What is the thinnest plywood that can be joined at 90 degree panel edge to panel edge and still be strong?

Thanks ahead of time!

[Rick]

I think 1/2 inch plywood (which is really 15/32 inch or 12mm thick) is the thinnest, but it presents challenges. 

I have some drawers to build, and I'm going to try to pocket screw 1/2 inch plywood (front and back) into 3/4 inch plywood sides.  I may even do a slight rabbet into the 3/4 inch ply.

[Edward Reifinger]

I have the Dewalt soft case for the track its very nice.  It looks somewhat like a gun case and has straps to hold the track.  

Kreg makes a mini jig just for 1/2" plywood