This wasn’t my first time working with the hand tools like drills and clamps, however it was the first time that I used table sanders and the router.  This was a fun challenge for me but I enjoyed it. I decided to try and attempt creating the box solo so that at the end of this class I could take it home with me and I thought it would be a fun way to learn how to use all the tools that are needed to make the crate.

Lets get started:

I started this project with precut planks. I decided to follow the design given in the making the box document. To begin I got myself a drill and three different attachments, one for counter sinking my screws, one for the pilot hole, and a bit to screw in the screws.  After this I grabbed some corner clamps to clamp my corners and then some clamps to clamp down the corner clamp and got to work.

My first step was to make the outside edges of all the layers first. I did this using the corner clap and the drill.

I also wanted to add a handle to my box so I measured out where I would make the cuts on the side planks.

I then used a jigsaw to cut out the handle by making small cuts in and then breaking off the pieces. From here I used a file and sandpaper to round the edges and shape my handles.

After putting together the outer frames. I moved on to making the base of my box. I grabbed three of the provided pre-cut planks and laid them in the bottom of one of my frames. My planks were a little to wide to fit in 3 abreast on the bottom. To fix this I used the belt sander to shave off the excess material on the middle plank to make all 3 fit.

After getting all my outer frames and the base built I started sanding all the edges to prepare for routing. I started with 60 grit sandpaper then went to 120 grit once I had all my surfaces sanded at 120 grit I routing my edges.

After routing all my outer frames I sanded the box again at 120 grit and then moved to 320 grit. I then began the assembly of the box. I started by screwing in the first 1×1 post. To do this I used 2in screws and some clamps to hold everything in place. This was somewhat of a challenge because I couldn’t get a good angle to screw in the screws. To solve this I screw in the screws at a slight angle.

After completing each layer and spacing them by using a spare 1×4 planks to make sure that they were even spacing. I finally had my completed box. After this I went over my whole box again with the 320 grit sander.

Summary:

I learned a lot doing this project. I am happy with my box overall however there are a few things I wish that I had done or things that I plan to add. I wish that I had done a little bit more sanding of the edges and applied a finish to the box. In the future I want to add a board to the bottom of the crate as well on the inside to make it look a little bit more flush. I also completely underestimated how much time it would take for me to sand the box completely.

Estimating Costs:

Materials

Wood (1×4) and (2×2) = 20$

Screws = 4$

Labor

$15/hour for 10 =  $150

I didn’t include the costs of the Machines in the wood shop or at the tables

TOTAL:  $174