Hello again!
This week, we became familiar with woodworking machines and post-processing techniques to enhance the aesthetics of our final product: a crate. It was my first time using many of these tools, but I had a great time, and I really appreciate everyone who helped clarify my questions along the way!
Assembling the Four Sides
We used the pre-cut pieces already provided, including 9 x 14.5” long pieces of 1×4 lumber;
6 x 12” long pieces of 1×4 lumber; and 4 x 10-11” long pieces of 2×2 lumber. To assemble the four sides of the box together, we first marked the six, 12” long pieces of 1 x 4 wooden planks on each side: ¾” from the top and bottom and 3/8” from the edges. These measurements ensured even screw placement on the short sides, allowing for a secure attachment.
After marketing the planks with pencil, we used corner clamps to hold them in place. Specifically, we positioned a 14.5” plank next to a 12” plank, with screws securing the outer planks. To ensure proper alignment, we drilled pilot holes using a ⅛” drill bit and then created counter sinks with a 9/64” drillbit. We learned that we often needed to countersink deeper to achieve a flush look.
We repeated this process for each corner until all four sides were securely together. Some sections were more difficult to align, and I had to resecrew a few connections while firmly pressing the corners together to minimize the gaps between the planks.
Routing the Edges
Once the two rows were assembled (we planned to add handles to the third row), I used a table router to round the edges. I chose a round over bit and routed all sides of the crate, including the vertical edges, for a smoother finish. If I were to do this again, I would increase the distance from the edges from ⅜” to ½” to avoid getting close to the router bit on certain sides.
Sanding
Before final assembly, I sanded all the planks and assembled sections of the crate. I started with a 60 grit sandpaper, sanding by hand, before using the 120-grit hand sander for a smoother finish. One of our planks had an odd angle, but after sanding, it removed some of the brown residue from earlier cuts and created a more polished surface. Since some of the edges were rough from routing, I used the sander to further smoothen them out.
Assembling the crate
To attach the bottom planks, I first placed three 14.5” planks side by side and positioned the bottom row of the crate on top, pushing down. It was a tight fit but ensured proper alignment.
Using a pencil, I marked 1”, 3”, 5”, 7”, and 9” at ½” from the bottom on the short wooden planks for screw placement. I then drilled pilot holes with a ⅛” drill bit and countersinks with a 9/64” drill bit. However, on the first side, the screws were slightly misaligned because I initially thought ½” was too high. As a result, there is a slight V-shape in the alignment. In the future, I would ensure both sides are evenly positioned, matching the more precise alignment of the second side.
Attaching the vertical columns
After sanding all four vertical columns with a 120 grit sandpaper, I made markings 2 inches from the top and 4.5 cm from the side to ensure even placement. Each vertical column was attached to the corner of the crate for maximum stability. Cali repeated this process to add the second row and later on for the final row, using the extra 1 x 4 lumber as spacers for consistent spacing. Instead of using one hole, she drilled two holes on the long plank for increased support.
Making the handle & Staining
For the final row, we decided to add a curved handle. Cali first outlined the handle dimensions in pencil (6″ x 1.5″ with an angle 1″ from each side) before using a jigsaw to cut it out. Since the shape was curved, she made multiple cuts before sanding it down to achieve a smooth finish. The handle was then securely attached using the same screwing and assembly methods described earlier. Finally, Cali applied Dark Walnut Wood Stain to enhance the wood’s finish, sanding it as needed, before allowing it to sit for 24 hours to ensure it fully dried.
And with that, we had our final crate that we store our future engi projects in! We did a great job in spreading the process over multiple days, which helped us understand the importance of reiteration, whether it was adjusting screw placements, sanding rough edges, or fine-tuning the routing. In the end, I had a really fun time working on the project with Cali and learning how to use the various equipment in the wood shop!
Photos of Cleanup
Cost Analysis
| Materials | Quantity | Price |
| Screws | 1 pack of #8 x 1-1/2 in. screw (1 lb.) ~ need 52 screws | $11.97 |
| Wood Planks | 2 planks of 1 in. x 4 in. x 12 ft. (to be cut into desired dimensions + extra) | $26.64 |
| Wood Post/Vertical Columns | 1-1/2 in. x 1-1/2 in. x 3 ft (with excess) | $10.92 |
| Dark Walnut Wood Stain | One 8 oz. container | $7.98 |
| Labor | 24.06/hour for 12 hours | $288.72 |
Total: $346.23
