For this project, I worked with Ben Henderson, and we completed this box over the course of three separate days. Initially, we were set to begin by cutting our own material, but Dr. Wettergreen notified us that there was extra pre-cut material we could work with! Thus, our build-a-box journey commenced!

09/06/2022

We began our project by assembling the four sides of our box to create the frames using the 1×4 lumber. To do this, we used corner clamps to secure the planks and line up the ends. We each did this on either side of a table so as to complete all corners of the frames in a timely manner.

To fasten the pieces together, we first drill holes using a 3/8 drill bit – spacing the holes exactly one inch from the top and bottom edges, respectfully.

Then, using 2″ wood screws and an impact drill, we screwed the 12″ piece into the 14.5″ piece.

Following the assembly of the first two corners, we clamped them down to the table and sanded the joints on either side using 80 grit sandpaper. Next, we clamped together our 1×3 baseboards, making them flush on one side, and sanding the other side down so as to have them all flush and equally lengthen.

Moving forward, we realized that we could be even more efficient with our time. So, while Ben assembled the remaining two frames, I sanded the faces of the baseboards as well as the 2×2 pieces using 80 grit sandpaper.

Unfortunately, during this time, Ben incorrectly assembled one of the frames by fastening the 14.5″ pieces into the 12″ pieces, rather than the opposite.

This was where we decided to end our hard day’s work. Although we may have ended on a low note, we had a few ideas and backup plans under our sleeves!

09/08/2022

I began the work day by going into the wood shop and cutting out new material to assemble a new frame so as to replace our defective one. Unfortunately, the new wood was slightly, but noticeably thinner than the pre-cut material provided to us. Thus, to maintain consistency, Ben and I agreed to reuse our original faulty frame, and attempt to use wood putty to fill in the drilled-out holes and somewhat restore its structural integrity.

While Ben created a wood putty concoction using wood glue and sawdust, I headed over to the wood shop to trim the edges of the 2×2. Without thinking, I rounded the first 2×2 piece on all sides. When I went to see how it look on a corner of our box, it was not flush, and did not look as aesthitically pleasing as I’d like it. Thus, I decide to only round three of the sides on the remaining 2x2s, keeping one side at a right angle so as to be flush against the corners of the box.

Next, we moved on to assemble our box. We placed our three bottom planks inside one of our frames. Then, we fastened the frames into the ends of the base planks, applying the countersinking method provided to us.

We then began to individually add the 2×2 pieces to the corners of the box. We fastened the 2×2 pieces into the 12″ pieces so as to reduce the number of screws visible from the outside of the box and maintain a clean aesthetic look.

Unfortunately, I had to leave after we assembled the bottom frame and initial 2×2 fastening. Ben proceeded to finish assembling the following two frames!

09/11/2022

Ben could not be here over the weekend to finish our box, so I was tasked with finishing our box! I began going back and reviewing what we had completed so far. I noticed that some of our countersinks could’ve been better, so I went back and re-did ones where the screws were not flush against the wood.

As I was moving, turning, and adjusting the box, I found it difficult to handle, and decided right there and then, that our box NEEDED a handle. But, I wanted to go above and beyond, and do a semi-professional-looking handle! I envisioned a rectangular handle within the center of the top frame. Since my drawing skills are atrocious,  I decided to use the opening flap of a nylon glove box as a reference for size and shape. I measured and determined the center point of 12″ pieces as well as the flap and traced the cutout onto the wood – having a perfectly centered handle!

Since I was not making a handle that began at an edge, I had to get innovative. I used a 5/16 drill bit to make a hole into the center point of the wood so the blade of the jigsaw could fit inside and I could cut outward from the center. I TIGHTLY clamped the 12″ piece using one of the clamps attached to the tables, and carefully and tediously cut out the handle shape.

Cutting was awkward as there was no proper place for me to do this type of cut. Because of this, the initial cutout was kinda rough. Nevertheless, I did it, and I managed to file and sand down the handle into a nicer and more consistent shape! I applied the same process to the other 12″ piece.

Once I reattached the 12″ pieces to the frame, I did some final sanding. I began with a 120 grit, followed by a 220, and ended it with a 400 grit sandpaper to get that nice smooth finish. As for the handles, I began with a 40 grit because of all the rough filing I had done. Then, I proceeded with an 80, followed by a 120, 220, and finally ended with a 400 grit to maintain consistent smoothness!

Lastly, we come to the finish. As with my apron, I am a man of simple taste, and I went with a simple natural look! I applied one coat of Watco’s danish oil across the entire box, waiting 15 minutes for it to dry before applying the second and final coat!

And with that Ben & Ricky’s Build-a-Box journey was complete! Hope you liked it!

Cost estimate

Materials

•  ~ 11′ of 1×4 lumber (~$6.50)
• ~ 6′ of 1×4 lumber (~$4) 
• ~4′ of 2×2 lumber (~ $2)
• 48 x 2-inch wood screws (~$3.50)
• Watco Danish Oil ($13.98)

Labor 

• 20 hours labor x $7.50/hour = $150 (split between two people)

Machine use 

• Assuming a $5/hour overhead for wood shop access multiplied by 11 hours shop time = $55

Total cost estimate = $235 per box