Antique White Crate!

• jjx3
Made by Justin Xia and Surina Kishinchandani
We started this project with pre-cut wood, which allowed us to focus on assembly and finishing rather than cutting boards to size. Laying out all the pieces at the beginning helped us see how the crate would come together.
To build the first frame, we clamped two 1×4 boards together, pre-drilled with a 1/8″ bit, counter-bored so the screws would sit flush, and fastened them with Torx head screws using the drill. Learning to pre-drill and countersink was new for us, and it was rewarding to see how much cleaner the joints looked compared to simply driving in screws. Once we got comfortable with the process, repeating it for both sides of the frame felt smooth and efficient.
With the two frames complete, we moved on to the bottom. We lined up three 1×4 planks across the frame, clamped them in place, and secured them with screws. This step showed us how important alignment is, since even small shifts early on affected how square the crate felt later. We also routed the bottoms of the frames to create rounded edges. Using the router for the first time felt a little intimidating, but it was exciting to watch the rough edges turn into smooth curves so quickly.
For the top frame, we created handles. This was one of the most enjoyable parts because we got to use the bandsaw and spindle sander in the OEDK shop. Cutting the openings with the bandsaw required patience, and shaping them with the spindle sander showed how the right tool can make the job much easier. Afterward, we finished the handles with 120-grit sandpaper by hand. Seeing them go from rough cuts to smooth, comfortable grips gave us a sense of progress.

We then moved to final assembly. Four 2×2 vertical supports were attached to the bottom frame with countersunk screws. We placed the second frame above the first, using extra 1×4 pieces to keep spacing even, and secured it to the supports. We repeated this process with the top frame and handles. Watching the crate take shape step by step was satisfying because each layer built on the work we had already done.

With the structure complete, we focused on finishing. We sanded the crate with 60-grit paper to remove rough spots, then used 120-grit and finally 200-grit for a smooth finish. Using the orbital sander was especially helpful, and it showed us how much faster and more consistent sanding could be compared to doing everything by hand. Running a hand over the wood after each pass made it clear why moving through different grits is so important.

Finally, we filled any extra holes with a mix of sawdust and wood glue, then applied antique white stain twice for color and protection. Staining was another highlight because it revealed the wood grain and tied the whole project together. Seeing the raw wood transform into a polished crate felt like the payoff for all the earlier work. Hopefully the crate will last a long time!
This was a very satisfying project! Here’s a picture of our cleaned up workspace.

Cost Breakdown

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