Project number two!!
To bring my wooden crate to life, I started by gathering the wood. I completed this project individually, so I decided to start with precut wood. The starting wood included:
- 9 x 14.5” long pieces of 1×4 lumber
- 6 x 12” long pieces of 1×4 lumber
- 4 x 10-11” long pieces of 2×2 lumber
First, I ran all my wood through the planer. This removed many of the imperfections and discoloration on the top layer. I then sanded all the wood multiple times. I used 5 different grits to achieve as smooth wood as possible. Although it took a long time and was quite hot outside, it was definitely worth it. The order of my grits was 60, 100, 240, 320, and 400. I choose to sand before construction to have easy access to all the sides. If the crate was already put together, the sides would be close together, so I would have to hand-sand to get all the edges. Sanding first allowed me to use the orbital sander.
Next, I worked on the handles. I drew out the outline as well as vertical lines going down. These vertical lines were the first cuts I made on the bandsaw. This allowed smaller pieces to break off as I began getting closer to the line. It also allowed for a tighter turn that I would not been able to do on the bandsaw if I just tried to cut along the outline. After cuttings, I cleaned my workspace by vacuuming the sawdust. I hand sanded along the new handles to straighten and smooth.
I then began the construction of the crate. I lined up the two sides of the box in the corner clamp. The desired dimensions of the box are 12 by 16 inches, so I make sure the butt of the 14.5″ piece was into the 12″ piece. I then clamped the set up to the table. For every screw I added, I just made a pilot hole using the 1/8″ drill bit. I then used then the larger drill bit to create a shallow, larger diameter hole to counter sink the screw. This allowed for the screw to not stick out of the wood when inserted. I then added the screws using a Phillips head bit. I repeated this process for all the screws.
Now that I had one frame, I repeated the process to create an additional two. I then added the three 14.5″ pieces to be the base. I added the two pieces flush against the sides first. I then used popsicles sticks in between the wood to space out the middle piece evenly. I clamped and repeated the screw process above each time.
Next, I used the table router to route the edges. I only wanted the exterior sides rounded, so this step could be completed after construction. Routing the pieces together also created a cleaner, level look because it minimized any areas where the two sides were not perfectly lined up. I routed all three layers on all exterior sides parallel to the base. I then cleaned up by workspace by vacuuming.
I added four vertical supports next. I screwed the 2 by 2s in, using the same screw process, to both sides of the base frame. I had already sanded these pieces earlier, so I didn’t have to worry about how I would get into awkward areas. I then used scrap plywood to evenly space out the next two layers. I then screwed those in too.
With the crate assembled, I went outside and did one final sand. I focused on the bottom of the base to level out the slight edge of one corner. After sanding, the two pieces were level and smooth.
I then moved on to my final step of post-processing. I chose to stain my crate in the color dark walnut. I applied one coat to the entire interior and exterior of the crate. Then I left it dry for two hours, as instructed on the can, and came back and checked if it needed another coat. I decided I liked the way it looked as is. Crate complete!!
Clean workspaces!!
Cost Breakdown
Materials
- 1.5″ long wood screws – $6.87
- 3 pieces of 1x4x8 lumber – $25.95
- 2×2 lumber – $4.98
- Wood stain – $26.96
Labor
I worked on this crate for 8 and a half hours. Assuming I am making $10 per hour once again, the total labor cost would be $85.
Tools
The OEDK kindly provided all tools necessary to complete this project, so those will not be included in the cost. Those tools included: corner clamp, table clamp, drill, ⅛” drill bit, Philips head driver, 60/100/240/320/400 grit sandpaper, orbital sander, router, planer, and bandsaw and miter saw.
Total Cost: $149.76
