As usual here is a song that you, dear reader, can listen to while reading this post. This piano song called “Black Earth” is from Fazil Say, an internationally renowned Turkish pianist.

In this project, Tinghan and I embarked on a project inspired by the fervor of collegiate rivalry – the Bayou Bucket, a monumental clash between the Rice Owls and the University of Houston Cougars. Our design choice leaned heavily on the symbolic colors of Rice – a soothing Rice blue juxtaposed with white, encapsulating the institution’s rich history and legacy. The Rice University logo, prominently displayed on the top of the box, was a mark of distinction, signifying the brand and its importance in this storied rivalry.

After finishing, celebrating the Rice Owls’ victory added an additional layer of excitement and relevance to our project. Go Owls!

PREPARING MATERIALS

Cutting the wood! We skipped the pre-cut option and went DIY. Since we started the project quite early we were able to work in peace and practice with the machines. Despite considerable practice, I still find the machines intimidating due to their significant potential for accidents. We tried to choose the cleanest and smoothest logs to decrease the amount of post-processing required. To ensure uniformity, we used a support piece that positions the log at a specific length beneath the rotary saw. We cut the pieces below:

• 9 pieces of 14.5 inch 1*4
• 6 pieces of 12 inch 1*4
• 4 pieces of 10-11 inch 2*2

ASSEMBLY of The Layers

The box is designed with three outside layers, each connected by four columns. Our first step was to assemble these layers.  For assembling the corners of each layer, we used a V-shaped apparatus. We adjusted the guide to 3/32″ and made countersinks for the screw heads (though I couldn’t recall the exact dimensions of those countersinks). With wood screws, we then connected the four pieces together to complete one layer. We followed this process for all three layers.

PosT PROCESSING STEP 1: ROUTING & SANDING

We aimed for our box to have smooth upper and lower corners, so we utilized a machine known as a router table. While its setup posed some challenges, assistance from the OEDK staff ensured its flawless operation. I was thoroughly pleased with the corner results. Subsequently, we refined the box using two different grades of sandpaper (80 then 120) to achieve a smooth finish.

 

 

Later on, we noticed our box didn’t have a handle. So, we made one. When adding the handle, we also cleverly cut the small black dent on the side of the box. We then saved the handles with 80, 120, 200 girds respectively. It turned out to be great!

 

ASSEMBLY OF THE BOX

To our surprise, upon initial assembly, we discovered that the two wooden pieces designated for the bottom were shorter than required. This minor setback saw us retracing our steps to the woodcutting workshop, where we rectified the error by cutting two appropriately-sized pieces. With the correct pieces in hand, we smoothly transitioned to the assembly phase. The bottom pieces were meticulously combined with the bottom corner layer, ensuring stability and precision. Following this, we proceeded to mount the four columns, which would serve as pillars for the structure. Lastly, the upper two stages were gracefully set atop these columns, completing our assembly with finesse and accuracy.

Post Processing Step 2: Painting

We chose navy blue for our box because it’s close to Rice blue. For painting, we used a bristle brush and water to thin the paint. But soon, we noticed that this method took much longer than spray painting. Honestly, I wish we’d used spray paint because it gives a smoother finish, is easier to use, and is much quicker. Lesson learned: next time I’m painting wood, I’ll likely go with spray paint.

Cuttıng the PATTERN FOR THE LOGO and paıntıng ıt

Upon discussion, I chose to use a vinyl cutting machine to craft the template for the Rice logo. Tinghan suggested we also add our names to the box, so I prepared another template for that. Working with the vinyl machine was a pleasant experience for me. ix in the upcoming week.

 

 

Once the templates were ready, I attached them to our painted box and used spray paint for the logo and our names. Sadly, the masking tape I used wasn’t tight enough, allowing some white paint to seep onto the box. While I attempted to sand away the excess, it seems the best solution is to repaint the affected areas. I plan to tackle this in this week.

 

Here is the result!:

WHAT I LIKED ABOUT THIS PROJECT:

This project offered a delightful blend of creative freedom and learning. Being able to choose designs and colors that resonated with the Rice theme made the process engaging. An added highlight was my introduction to the vinyl cutting machine, which provided an exciting hands-on experience. Moreover, collaborating with Tinghan added depth to our decisions, such as the thoughtful addition of our names on the box. Seeing our ideas materialize into a tangible product was the cherry on top, giving a unique sense of accomplishment.

ROOM FOR IMPROVEMENT:

Our choice of materials, especially the masking tape, presented some challenges. It failed to create a tight seal during the painting process, leading to unintentional paint seepage. This taught me the importance of thorough material selection and testing, ensuring fewer hiccups in future endeavors.

Cost of the BOX:

Cost Type		Price	Source	Quantity	Total
Materials	1*4 Lumber	9.69 (4ft)	ACE	202.5″	40,88
	2*2 Lumber	3 (3 ft)	ACE	44″	3,67
	Spray Paint	5.98 (1 can)	Walmart	0.1 Can	0,59
	Paint	22.62 (32 oz)	Walmart	10 oz	7,07
	Bristle Brush	0.98 (1 pc)	Walmart	2 pc	1,96
	Sand Paper	6.98 (4 pc)	Homedepot	4 pc	6,98
	Wood Screw	44.97 (1467 pc)	Homedepot	40 pc	1,38
Labor	Carpanter	21.95 / h	Ziprecruiter	4 h	87,8
	Prototyping Eng.	53.93 / h	Zippia	0.5 h	27,0
Overhead	Vinly Machine	25 / h	Not found	0.5 h	12,5
	Drill	16 / 4 h	Homedepot Rental	1.5 h	5,63
	Orbital Sander	13 / h	Homedepot Rental	1 h	13
	Cutting Workshop	43 / 4h	Homedepot Rental	1 h	10,75
Design	Vinly Paper	65.28 (720″)	BHP	30″	2,72
Miscellaneous	Mistake 1*4 Lumber	9.69 (4ft)	ACE	29″ (2 pc)	5,85
				Total	227,74

Comments on the cost:
Given that the average price for a basic box on Amazon ranges between $30 and $45.6 , the costs associated with the proposed model appear to be not sustainable.