This weekend, we learned and practiced the skill of woodworking through creating a wooden box.

 

The Preparation:

First, we picked out a long piece of 1 x 4 lumber and measured out and cut it into 9 x 14.5″ pieces and 6 x 12″ pieces. We also grabbed 2 x 2 lumber and cut it into 4 x 10″ pieces. We did this cutting process using the miter saw.

We then ran all 4 edges of each piece of wood through the router in order to create a smooth feel.

After cutting and routing the wood, we had what was needed to begin the construction of the crate.

Crate Construction

First, we gathered the necessary materials, a power drill, 1.25″ wood screws, a 1/8″ drill bit and a 5/16″ drill bit, Philips head bit, corner clamps and table clamps.

We began by making 3 rectangle pieces that we would later assemble together into the box body. To do this, we butt up a 12″ wood against a 14.5″ piece of wood. We secured it with corner clamps and table clamps. We then drilled pilot holes using the 1/8″ drill bit. Then, using the 5/16″ drill bit, we created a chamfer over the pilot hole for the screw to sink into. Finally, I used the Phillips head bit to secure the wooden screws into the pilot holes.

We then repeated the process 12 times, joining the corners together to create 3 wooden rectangles.

Using the same screw assembly method of clamping down the wood, drilling pilot holes, chamfering and screwing in, we joined 4 x 14.5″ planks onto the bottom of one of the rectangles. This is supposed to create the floor or the bottom of the crate.

We then aligned the four 10″, 2×2 pieces of wood standing within all of the 4 internal corners of the previously created shallow box and secured them using the wood screws. These will act as the supports for the body of the box. Then, we slipped one of the hollow rectangles we created in earlier steps over these standing pieces supports. We also used 2 pieces of 1×4 scrap wood to space out the hollow rectangle from the base of the box.

We then repeated this process for the last rectangle of wood and began post processing.

Our first step in post processing, we sanded the entire box, slowly increasing the grit of the sand paper to reach a very smooth finish.

After sanding the entire box, we then stained the entire box using a “barn red” stain. To do this, we painted the entire box in liquid stain and then wiped off the excess stain after some time.

Then we set out the box to dry. The box is now complete!

 

Cost Analysis:

Materials

(9 x 14.5″ ) + (6 x 12″) of 1×4 lumber @ ($6/8ft) =  $12

(4 x 10″)  2 x 2 lumber @ ($4/8ft) =  $4

67 wood screws @ ($4.44/100) =  $4.44

Stain =  $8.97

Machine Time

$30/hour for 3 hours =  $60

Labor

$15/hour for 8 hours for 2 people =  $240

TOTAL:  $329.41