This past week I was assigned to build a crate with a partner. My partner for this project was Cameron Monroe. In my opinion this project was a bit easier to navigate compared to the apron project because by being in pairs we were able to troubleshoot more efficiently and quickly. Going into this project I did have some experience with power tools and working with wood, but not enough to be considered proficient. Overall throughout building the crate, I believe I have grown more confident in working with wood and troubleshooting. 

THE PROCESS:

At the start of this project we were given the options to either cut our own wood or have the wood pre-cut for us. The wood that we utilized to create the crate was 1” by 4” lumber of different lengths (14.5” or 12”) and 2” by 2” lumber with a length of 11”. In total we had 4 pieces of the 2×2 lumber, 9 pieces of the 14.5” 1×4 lumber and 6 pieces of the 12” 1×4 lumber. We decided to choose the pre-cut wood, as it would cut down on time.

(Some pieces of the pre-cut wood)

Afterwards, we joined 2 pieces of the 14.5” and 12” 4x1s together using 1.5” wood screws to create the base frame of the crate and then using the table router we routed the outer edges of the frame.

(We used corner brackets to assemble all the frames of the crate.)

(Using the table router to smooth out the edges of the frame)

Next we took the 3 base panels (14.5” 4×1 lumber) and attached them to the inside of the base frame. For the base panels we chose the 3 panels that we determined were not the best shape aesthetically. Then we attached the 4 inner 2×2 pillars. 

     

(When we assemble the inside of the base we, kept the more aesthetically pleasing side of the panels inwards. Then using clamps to hold down our base we screwed in the pillars)

Afterwards we constructed the other 2 frames of the crate and routed the outer edges once more. Then we attached the 2 frames to the inner pillars to assemble the crate in its entirety. This is where we ran into a little bit of trouble as fitting the remaining 2 frames over the vertical pillars. To solve this issue we used clamps and our hands to push the inner pillars inwards while fitting the 2 frames over them. Once the crate had been assembled we began sanding the exterior of the crate to begin our post processing. To sand the crate we utilized an orbital sander with 120 grit sandpaper.

(This is our first round of sanding after getting the two frames over the inner pillars, then we screwed in the top two frames and conducted another round of sanding.)

(This is what our crate looked like after the second round of sanding before spray paint.)

After all the sides and edges were smoothed out, we decided on how to “color” the wood. For this we decided to spray paint the wood.

(Applying the initial coat of spray paint.)

We started out with the bottom of the crate so that when we started spray painting the outside and inside of the crate the base would already be dried. After applying 2 coats of blue spray paint, we decided to add in a little bit of personality to the crate by peppering white spray paint on top.

(The final product sitting on the drying rack to dry.)

 

The overall finished product in my opinion looked very well aesthetically speaking.

       

(Images of the finished crate.)

Below is a cost model for this project.

Cost Type	Cost	Price	Source	Quantity	Total
Materials	1x4x12 Board	$11.97	https://www.homedepot.com/	2	$23.94
	Screws (110 pk)	$12.38	https://www.homedepot.com/	1	$12.38
	Sand Paper (orbital)	$9.97	https://www.homedepot.com/	1	$9.97
	2 in. x 2 in. x 8 ft.	$4.98	https://www.homedepot.com/	1	$4.98
	Spray Paint	$9.99	https://www.michaels.com/	2	$19.98
Labor	Woodworking Operator	$18.20/hr	https://www.ziprecruiter.com/	1/hr	$18.20
	Prototyping Engineer (You!)	$36.48/hr	https://www.ziprecruiter.com/	6/hr	$218.88
Overhead	Facility Cost (Machine Time)	$50/month	https://apps.txrxlabs.org/join-us/	1	$50.00
Design	Engineering and Development	$60.70/hr	https://www.talent.com/	1	$60.70

The total cost according to this model came out to be $419.03. This is significantly higher that what I expected it to be, however not all the materials purchased would be used in its entirety. Such as the screws or the spray paint, which could be used in other projects or other iterations of this crate, reducing cost if we were to manufacture this at a large scale. Most of the cost however, stems from the labor, which is something that would not be reduced even if we upscale production, as this model does not cover quality control and there would probably more time invested in the engineering and development of the crate. If I were to redo this crate I definitely feel confident that I would be able to reduce the amount of time required to build this crate by half. 

(My workspace after finishing everything.)