For my first ENGI 210 project, I worked with Art to build a crate. We started out with pre-cut wood that had been cut and portioned out to build out a 16”x12”x12” (LWH) storage box. However, we soon ran into our first issue when some of our wood had major defects. Luckily, after learning how to use the miter saw in class, it was simple to cut a few replacement pieces of wood to the right length.
Figure 1: Drill bits used.
Next, we started to build the three frames of the box using four pieces of 1×4 lumber and construction wood screws. We used cordless drills with three bits: a pilot bit, a countersink bit, and finally a Phillips head bit, laid out in figure 1. It took eight screws (two on each corner of the frame) to assemble each frame, and each time we drilled we used a combination of c clamps and a corner clamp to keep the frame in place.
Figure 3: Sanding Pieces
Figure 2: Routing Edges
After assembling the frames, we moved on to post processing prior to assembling the crate. We started with using the hand router and a round over bit to go over all the frames on all sides, shown in figure 2. We also used the table router with a round over bit for the pieces of lumber that would be used as the base of the crate. Finally, we used a progression of sandpaper to smoothen the wood, ranging from 60 grit to 400 grit, shown in figure 3.
Figure 4: Applying Stain
Once all the pieces had been post-processed, we proceeded with our first coat of mahogany gel stain, shown in figure 4. After letting it dry, we started to assemble the crate before running into our second major problem. We mistakenly used a pilot bit that was too large for our construction screws. Determined not to resort to wood glue, we slimmed down a dowel and used it to fill the pilot hole with the, then went through with the construction screw.
Figure 5: Applying Clear Coat
After fully assembling the crate, it was time for a few finishing touches. After further sanding with high grit sandpaper, we applied one more layer of gel stain and letting it dry overnight before finishing the crate off with a gloss clear coat shown in figure 5.
Figure 6: Completed Crate
Figure 7: Example of Cleaned Workspace
The completed crate can be seen in figure 6. For our first project, Art and I learned a lot about both the making process and the techniques used behind building a wooden crate. Throughout this assignment, it was vital to maintain a clean workspace, with figure 7 showing an example we kept such workspaces clean after using them.
Finally, I have included a cost breakdown including all the consumables used for the project along with estimate for the labor involved below as a reference:
| Item | Quantity | Estimated Cost ($) |
| 1×4 lumber | ~ 15ft | 8.00 |
| 2×2 lumber | ~ 4 ft | 3.00 |
| Construction Screws | 36 | 2.50 |
| Mahogony Gel Stain | 1/10 Can | 2.50 |
| Gloss Clear Coat | 1/10 Can | 1.00 |
| Sandpaper (Variety) | 4 sheets | 2.50 |
| Labor | 20 hrs @ $10/hr | 200.00 |
| Total Costs: | 219.50 |
