For this project, I worked with Sophie:
Our goal is to create an open-top crate made of planks of 1×3, 1×4, and 2×2 lumber.
1. Preparing the materials / Cutting
We first used a pencil and a tape measure to mark the correct dimensions for each piece and used a miter saw to cut them. Some pieces were longer due to confusion about kerf, so we corrected them with the miter saw. We then used a jointer and a planer to straighten edges and create smooth surfaces. We also used a router to round some of the edges. However, we realized that we could’ve used the router before assembly to reduce the sharp corners. At that point, the screws were too close to the corners for the router to be used without redoing the screws.
Lesson learned: try assembling without screws first to verify the results.
2. Assembling
We screwed everything from the outside, resulting in many visible screws. Painting the project helped hide the visible screws, but for future projects, I would consider screwing from the inside or using a kreg jig to minimize their appearance. We used scrap wood to maintain equal spacing between the three frames. However, attempting to screw the bottom piece to the bottom frame was challenging due to the limited adjacent area, leading to a cracked surface and the need for a rescrew next to it (as seen in the right of the above picture).
3. Post-processing
We first used the electric sander and sandpaper by hand to smooth out any rough spots. The process was smooth, with Sophia handling most of the sanding while I was absent.
However, painting the crate didn’t go as I expected it to. Being too close and spraying for an extended period caused the surface to have an overt overspray appearance. Due to the limited time we had, we also did all sides at once, leading to drip marks from gravity. In the future, I plan to have each side facing upward and paint them one at a time. Even after applying a second coat of paint, it still appeared uneven. To create a space-like effect, I added splashes of white paint, which also helped with covering the blue paint’s unevenness. Despite the dripping marks, I liked the result and would add some purple in the future for a more cosmic look.
The final outcome was a product of teamwork and effort put in by Sophia and me. Despite some challenges, we managed to create a unique piece that we are proud of.
Cost estimate:
Two 8′ x 1″ x 4″ planks: 2*$3.38 = $6.76 (Lowes)
One 8′ x 2″ x 2″ planks: $2.98 (Home Depot)
One box of wood screws: $10 (Home Depot)
Blue and white spray paint: 2*$6.50 = $13 (Home Depot)
~6 hours of work: 6*$20 = $120
TOTAL: $152.72
