Our second assignment in ENGI 210 was to make a securely fastened, five-sided wooden box. I was immediately intrigued by this assignment and was excited to get to work as soon as possible. However, it was not long before many members of the class had completed their own boxes or shared information about their finalized design ideas. I soon realized that most of the straight-forward approaches to building a box were taken. I wanted to created something original and build something outside the box.

I researched many different types of wooden boxes, and was ultimately inspired by paneled wooden crates. I decided that I wanted to build a box with sides consisting of multiple wooden boards fastened together by vertical wooden supports in the inner corners of the box.

I made my way to the wood shop where I found a long, uniform  1 by 4 inch plank of solid pine, a large 2 cm thick square piece of pine, and another large square piece of 1/2 inch layered plywood. With all of my materials for the various components of my box, I was ready to begin cutting!

I first measured out a 6 by 6 inch square on the layered plywood for the base of my box and cut it out using the circular saw. Next, I measured out 8 six inch sections of the thin plank and also cut these out using the circular saw. These would later comprise the walls of my box. I again used the circular saw to cut four 2 cm thick dowel-like strips out of the large plank of pine, each 6.5 inches long. I later incorporated these pieces as the inner supports of my box. With all of my wood properly cut out, it was then time to use the router!

I decided to round off the lateral, outer edges of all eight side panel pieces to add detail and a smoother aesthetic to my intricate design. I then transported all of my pieces from the wood shop down to the working tables in the basement of the OEDK to assemble!

I first laid out and stacked the pieces to form an optimal configuration, because due to the fidelity of the wood and my imperfections as a woodworker, not all of the matching pieces were identical. Before fastening any pieces together, I used the band sander to sand out triangular slopes on the support beams to add detail to the interior of the box. I then began by drilling No. 6 one inch flat Phillips head wood screws through the cubic dowels into the side wall panels. I created 2 L-Shaped components that fit together to complete the box…

I then carefully fastened both L-shaped pieces together. I found that using a screwdriver to insert the screws gave me more control and feel compared to a power drill, considering this was a tricky angle to screw and the wood was delicate….

After the outer frame of the box was complete, I carefully placed the walls over the 6″ by 6″ base of the box. As one may have predicted, the frame no longer fit perfectly around the base, so I had to return to the band sander and sand the base piece down a tad. Soon enough, however, the dowel-supported frame fit nicely around the base and the last step was to simply screw the corners of the base into the four dowels through the bottom side of the box.

I am proud on my final product for this project. I think my design is original and more elaborate than simply screwing five pieces of wood together. I had a lot of fun and am looking forward to my future ENGI 210 adventures!!

Cost Reflection

After researching the materials I used, I found that all of the wood components I used most likely add up to less than 5$. As for the screws, all twenty screws combined costs less than 1$. I did, however, spend over five hours in the OEDK measuring, cutting, and assembling my box. Therefore, if I were to sell it, I would charge for time of labor, as well. I did also use a number of complex tools, including the circular saw and the router. Industry average for overhead, consisting of machine rentals and utilities, tools, glue, etc., is 15 percent of the finalized materials and labor pricing. Moreover, if I charge 5$ an hour for labor (because, honestly, I’d do it for free because its fun!) and the total price of the materials is 5$, 15% of 30$ is $4.50. The total price of my box would be $34.50.

References:

Box Inspiration:

https://i.pinimg.com/originals/63/1c/bd/631cbdeec0751057c30b8e57a79cbb5f.jpg

Cost Research:

https://www.homedepot.com/p/Grip-Rite-6-x-1-1-4-in-Philips-Bugle-Head-Coarse-Thread-Sharp-Point-Drywall-Screws-1-lb-Pack-114CDWS1/100152392

https://www.homedepot.com/p/1-in-x-4-in-x-6-ft-S4S-Whitewood-Board-0000-914-673/302172512

https://www.rockler.com/how-to/set-price-woodworking-projects-home-workshop/