For this assignment, I created a box using the beginner guidelines.

Measuring and Cutting:

The most arduous part of this process started with measuring and cutting the 1/2 inch thick wood into the correct sizes. First, I used the tape measure to mark off one 11.5 in by 15.5 in a piece of wood so that when put together the thickness of the wood is taken into account to make a 16 in x 16 in x 12 in box. As shown below, I used the table saw to do my cutting. After making one cut, I used it as referenced when measuring the other pieces as shown below.

After cutting out the 16 in x 16 in piece I used the jointer to straighten out the sides of each piece and make sure the 11.5 in x 15.5 in pieces were all the same size. 

Routing:

After ensuring all the pieces were the correct size, I used the router to curve one edge of each side piece and all edges/corners of the bottom piece. I kept the top edge of the side pieces straight to keep the box looking somewhat professional (at least in my opinion). 

Screwing:

Next, I had to screw the pieces together. I used a combination of the corner clamps and regular clamps to make the initial screws as shown below.

Before screwing in the screws with the power drill, I used the 1/8 in drill bit to clear out material in order to avoid the wood cracking from adding too much mass from the screw

 

 

 

 

 

 

 

Unfortunately, in one instance I didn’t clear enough material causing the wood to break apart as I was screwing together the boards. Then in an attempt to relieve the pressure from the screw, I unscrewed the screw then used the drill bit to clear out more materials. That is when as I was taking out the bit, it broke up lodging itself into the board as shown below. Thankfully it’s doing a good job at keeping the box together.

Sanding:

After putting the box together, it was time to sand the box. As you can see below, the sides weren’t exactly flush since it is difficult to get all your measurements and cuts correct without accounting for how the board morphs when screwed together.

I first used the electric iron-shaped sander with the 80 grit size for a rougher sanding to get more material off. Then I went over it with a 220 grit size for a finer finish. I then went over the curved edges with the paper 180 grit size sander to extenuate and smooth the routered curved edges.

 

 

 

 

 

 

 

The finished box is portrayed below. The final size came to 15 15/16 in x 16 1/8 in x 12 1/4 in which makes sense as the sanding and screwing could’ve caused changes in the intended size.

 

 

 

 

 

 

 

Cost:

Material:

– Plywood (Home Depot): (1 x (15.9375in x 16.125in) + 2 x (11.75 in x 15.625in) +2 x (11.75in x 15.4375in))*(32.67$/4608in^2)=$7

– Screws (Home Depot): (20 screws x 0.21$/screw)=$4.2

• Total Material Cost: $7+$4.2=$11.20

Labor:

– Measuring/Cutting/Routing: 4 hours

– Screwing/Sanding: 2 hours and 15 minutes

• Toal Labor Time: 4 hours + 2 hours and 15 minutes = 6 hours and 15 minutes
• Total Labor Cost: (6 hours and 15 minutes) x (11$/hr*) = $68.75

Total Overall Cost = $11.20 + $68.75 = $79.95

*Based off Lab Assistant Salary