This week was my first time building a box from scratch (or anything with screws for that matter). Most of my engineering design work thus far has been tied to product design and software development rather than physical products. Starting this project with no experience with woodwork, screws, and sanding, I knew I was going to need extra time and a lot of patience to complete this assignment.

I began early, signing up for pre-cut wood and getting into the project as soon as possible, not knowing how long it would take. My first rectangle was perfection — quick setup, simple screw work with no splitting of the wood. With one completed rectangle, I thought the project would be easy to complete but I was wrong as every following rectangle had problems. From wood splitting so wood pieces disconnecting after being screwed in, I really began to struggle.

I began coming to the OEDK every day to make little progress on my project. I originally had big goals of sanding and creating rounded edges, staining my box, and maybe adding lettering but I ended up barely creating a standalone box. Regardless of the long process, I am proud of my result, one sturdy and secure box. 

With more supporting screws and elbow grease, I was able to create a product and gain a skill I had never thought I would obtain. Additionally, I believe being left-handed presented more problems as I was struggling to emulate the class tutorials on my own.

Two of the biggest challenges that I am proud to have overcome are cutting down a plank of wood to fit the bottom of the box and sanding down the supporting pieces of wood so my rectangles could fit. Additionally, throughout the process, I learned that placing the screws closer to the corners would provide better support than the middle which was initially causing some looseness within my rectangles.

Materials:

• 1.5” screws → $5
• 9 x 14.5” long pieces of 1×4 lumber → $7
• 6 x 12” long pieces of 1×4 lumber → $5
• 4 x 10-11” long pieces of 2×2 lumber → $2
• Provided
  • Clamp
  • Drill
  • Sandpaper
  • Philips head driver
  • ⅛” drill bit

Labor:

• 25 hours * $20/hour = $500

Machine Use:

• $10/hour for wood shop access * 2 hours = $20

Total:

•  $500 + $20 + $19 = $539 / box