Team Members: Alexis Romano and Eli Rich
For the building of this crate, we decided to go with the intermediate route, as we both had some experience with woodworking and power tools. Based on the specifications, we designed the crate to be a 12x16x12″ crate. The dimensions are specified below.
Schematic of Wooden Crate
We first began by cutting our own wood. We began by marking one side of the 1×4″ plank to create a stencil for the other cuts we would make of the same length using the miter saw. We quickly cut all the pieces down to length, and then we would begin the assembly of the individual layers of the crate using countersunk wood screws.
Sizing of Wood Using a Miter Saw
Assembly of the Layer of the Crate
We used a bandsaw to make a handle for the top-most layer to make the box easier to carry (love ergonomic grips). We then routed some of the edges of the layers, especially the top-most one, using two different patterns. On being a rounding bit that just rounds the edge with the bit, while the other was a cove bit, which dug into the wood like a quarter circle. Once all the layers were assembled, we then proceeded to sand using orbit sanders, going from 100 grit to 240 to 320 all over the layers. We then finished off the sanding, doing 400 grit by hand all over, making sure to go into the routed edges for uniformity of the sanding finish. The sanded layers and pieces were then screwed in together, making sure the whole crate was flush, especially the top layers with the 2×2″ pieces.
Assembly after Sanding
Once we finished the sanding and assembly, we decided to add a finishing layer by staining our crate! We decided to use a water-based stain of dark walnut. We applied it liberally across the entirety of the crate and then followed the instructions, wiping it off after 3 minutes. And with that, we have a finished crate! Overall, I am relatively happy with the finish of the crate. There are some aspects that I wish could be improved upon, especially as, while I have drilled before, I had never done a countersink ever, so that is one aspect that could be better. But nonetheless, it is done.
Finished Crate
Doing a simple cost analysis, the materials used are as follows:
- 202.5″ 1×4″ lumber – $3.14/8ft * 2 (Home Depot) = $6.28
- 45″ 2×2″ lumber – $2.97/8ft * 2 (Home Depot) = ~$1.40
- T-25 screws – $49.48/1,842 pc (Home Depot) = ~$1.13
- Varathane Water-Based Wood Stain – $15.97(used <1/4) (Menards) = ~$4
The materials cost is around $12.81. Eli and I put in around 10 hours total working on this crate, and based on ZipRecruiter, an average entry-level carpenter would make $24/hr. I believe it would be fair that Eli and I would then have the skill to get paid at least $15/hr. This would put labor costs at $300 and the total at $312.81. If we include the costs of the equipment used….. I would definitely not buy this box. A drill itself will cost ~$100, depending on the brand of the equipment. A rough estimate would be around $350 if you tried going cheap, but the equipment at the oedk is not necessarily that. However, if the creation of these crates were scaled up and if there was a clear demand, then the cost of the equipment would become more manageable, but it would be expensive.
Works Spaces After Our Use
