Helloo!!
Welcome to another episode of me trying to put wood together. For this project, I partnered with Jolina. Our amazing teaching team was helpful to provide us with precut wood.
Fig 1. Precut wood
Jolina and I started the assembling the basic structures by using:
- 6 x 14.5” long pieces of 1×4 lumber
- 6 x 12” long pieces of 1×4 lumber
To build each rectangular frame, We joined two long pieces with two short pieces, using a corner clamp to hold them in place.
Fig 2. Clamping the pieces together
Fig 3. Making the basic skeleton and repeating the process
Joining the Pieces
Once clamped, we prepped the wood for screws:
- Countersinking – To make sure the screws sat flush, we used a regular drill bit roughly matching the screw head’s diameter. Initially, we used a smaller bit but later switched to a larger one to match better.
- Pre-drilling – A 1/8” bit made the drilling process easier.
- Screwing – Using a star bit, we secured the screws in place.
Fig 3.1. Various drill and drill bits
We repeated this process for all three frames before moving on to the finishing touches.
Sanding and Routing
Once assembled, the frames had rough edges and sharp corners, so we took time to smooth them out. We used a hand router to round the edges, setting the fence to an appropriate distance. Then, we ran each edge along the router bit to create a smooth finish.
Fig 4. After using an orbital sander
Sanding
After routing, we clamped down the frames and used an orbital sander to even out the surfaces. We also sanded:
- 4 x 10-11” long 2×2 posts
- 3 x 14.5” long bottom pieces of 1×4 lumber
Staining
This was the most fun part. With everything sanded and smooth, we moved on to staining. We applied the stain evenly to all pieces and left them to dry with repetitive stains. We were going in for a rustic look so we did repetitive staining in between and let it dry for a day. Due to the humidity, we realized that the stain hadn’t dried well.
Fig 5. Staining
Assembling the Crate
With all the pieces prepped, it was time for final assembly:
- Bottom Installation – We placed the three 14.5” long bottom pieces inside the frame and secured them with screws, following the same pre-drilling and countersinking method.
- Attaching the Posts – We positioned the 2×2 posts and secured them to both the long and short faces using screws.
- Stacking the Frames – Using spare wood as spacers, We aligned the frames evenly and secured them onto the posts.
Fig 6. Stacking and joining them in place
Finishing Touches
For the final step, We lightly sanded any remaining rough areas, particularly around the screw holes, using 440 grit sandpaper. We both were very happy about our crate. It had a beautiful rustic look and a great finish.
Fig 7. Finishing
Cost Breakdown
| Cost Type | Item | Price per Unit | Source | Quantity | Total |
|---|---|---|---|---|---|
| Materials | 1×4 Board | $0.36/foot | homedepot.com | 17 ft | $6.12 |
| Screws | $0.07/screw | amazon.com | 44 screws | $3.08 | |
| 440 Grit Sandpaper | $1.07/paper | amazon.com | 1 paper | $1.07 | |
| Labor | Woodworking (Me!) | $22/hour | ziprecruiter.com | 9 hours | $198.00 |
| Overhead | Tools | $642 total | homedepot.com | – | $642.00 |
| Total | $850.27 |
Wrapping Up
The best part? That satisfying moment of stepping back and admiring the finished product. Now, all that’s left is to add in all our fun assignments to the crate or maybe plan the next build. Either way, this was a solid week well spent.
Fig 8. Clean workspace
