Overview
For this project, I worked with Allison to create our own wooden crates. This process took a bit longer than anticipated but resulted in a product that I’m very happy with. Read on to learn more about the box and process!
Preparation and materials
First, we needed to determine the wood and lengths necessary to achieve a 16″ x 16″ x 12″. Considering that the 1×4’s are more likely 3/4×3-3/4’s and that the plywood is 3/4″ thick, we cut twelve 1×4’s to 15-1/4″ long for the slats, four 2×2’s to 11-1/4″ long for the supports, and a 12×12 piece of plywood was already prepared by Douglas. The lengths were cut using the miter saw. To ensure all pieces were the same length, the first cut was measured, and the rest were measured using the first cut as a reference. to ensure that we would be accounting for the thickness of the saw blade, we also individually measured and cut, rather than measuring out all the pieces from one plank in one go.
To refine the finishes on all of the cut materials, they were taken through a planer multiple times to ensure smooth faces. We then used the router to bevel the edges of the slats so there were no sharp corners. We also beveled one edge of each of the posts so that the edge facing inward would be smooth and the other 3 would not create mor nooks than necessary.
Assembly
Once all of the materials were cut and collected, we then headed downstairs to assemble. We wanted to ensure that our screws were only visible from the inside of the crate in the final product. For this reason, we started by creating two corners using the four bottom slats and the posts. We ran the screws through the posts skewed, mounting each slat to each post with two 1-5/8″ screws. We then mounted those corners to start our frame.
Our next step was to attach the base to the frame. Before we started though, I sanded the plywood as it would be hard to get into all the nooks after the whole crate was assembled. The attachment was then done by running a 1-5/8″ screw through the bottom of the plywood and up through each post. The screws had to be carefully measured and placed in order to ensure none of them collided and this was overall successful. From there, I then started working on the second row of slats, using the same plank of wood as a reference for the gap between rows. I finished up by attaching my final third row of slats.
Finishing touches
Once everything was assembled, it was time to do lots of sanding. Using the orbital sander, I made sure that all surfaces were flush and rounded out any and all corners to ensure that no one could cut themselves on the crate. After brushing off all the sawdust with a damp paper towel and letting the piece dry, we went upstairs and outside to complete our staining. We used a cherry stain to attain a redder finish, and applied a thin coat of stain using paper towels. These became very tedious, especially when trying to get into all the nooks and crannies, so there are a few sections that I wish I had noticed that I had missed in some crevasses. Additionally, I wish I had used a rag instead of paper towels as the paper towels kept falling about and leaving bits all over the piece. After 24 hours, I then applied a clear coat finish to protect the wood and have a nicer finish.
Summary
I was so excited about this project because it has been some time since I’ve used woodworking tools and the end result did not let met down. I feel like I now have a sturdy crate to hold the rest of my pieces that I will be making over the course of the semester.
If I were to redo this project, I think I would have tried to more carefully plan which slats I wanted to place where so that the best-looking ones would be on top. Additionally, I wish I was more meticulous about the screw placement when I first started because the placement of the vertical screws isn’t completely uniform. I also wish I had caught some of the staining misses in the nook and crannies.
Below is my cost estimate for this crate:
- Time: $155 ($20/hr for 7.75 hrs)
- Materials: $30.63
- Overhead: $30
Total Estimate: $215.63
