Hello ENGI 210! This week Ayaka and I made a nice wooden box 🙂

We used precut wood, so start out, we assembled the three rectangular perimeter pieces. We used the corner clamp to hold the wood in place with the 12″ pieces against the edge of the 14.5″ pieces. We first drilled a pilot hole, including a countersink, then drove screws in.

Once all three rectangles had been created, we used the router machine in the woodshop to round the edges. We had some issues with screws that were too close to the edge getting in the way of the router bit, but we were later able to sand out any missed pieces of wood. 

 

After this, we fit one of the rectangles with 3 more 14.5″ pieces to create the bottom. We had to sand some of the edges down quite a bit so that they would fit in the area created by the rectangle.

After drilling these pieces in, we aligned the 4 posts in each corner of the bottom, then clamped and drilled them in. We used two 1” thick wood scraps stacked on top of the first layer to ensure even spacing as suggested, then drilled in the second and third rectangular layers to the posts.

We had some issues with gaps being created, but adjustment of screws while clamping solved these issues as much as possible.

After this was done, the crate had been fully assembled and all that was left was to sand out any rough spots. We mostly used the handheld orbit sander over the entirety of the box. We started with 60 grit, then mostly used 100, and finished with 180. Throughout the assembly steps we had already sanded individual pieces to some extent, so we were mostly ensuring that the edges of the box were clean.

Cost estimate:

• • 9x 14.5” long pieces of 1×4 lumber = $7.10
  • 1x4x8ft = $3.55
  • 6x 12” long pieces of 1×4 lumber = $3.55
  • 4x 10-11” long pieces of 2×2 lumber = $3.55
  • 1.25” long wood screws = $7.20
  • Labor: 7 hours x $7.25/hour x 2 people = $101.50

  Total = $122.90