This week, Zoe and I used the woodshop and various post-processing techniques to build a crate to store all of our ENGI210 materials and projects! While I had used many of the machines and techniques in previous projects, I enjoyed working with Zoe and figuring out where everything was in the OEDK.

To assemble the crate’s bottom layer, we first marked the six, 12” long pieces of 1 x 4 wooden planks on each side with dots that were 3/4” from the top and bottom and 3/8” from the edges. These ensured that all of our screws were placed evenly.

After measuring and marking all the holes, we used corner clamps to hold the wood pieces in place. We positioned one of the 14.5” plank next to a 12” plank, and drilled preliminary pilot holes using a 1/8” drill bit, as well as counter sinks with a 9/64” drill bit. We learned that we often needed to countersink deeper, and with a wider drill bit, to achieve a flush look.

We repeated this process for all the corners of the first two layers of the crate, as seen below.

Once the two rows were assembled, Zoe employed a table router to round the edges, using a round router bit to smooth the horizontal and vertical edges. We liked the way the example crates were smooth to touch and wanted to see if we could replicate that.

Before final assembly, Zoe sanded the planks and assembled sections of the crate. She started with a 60 grit sandpaper, before using the 120-grit 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.

To attach the bottom planks together, we placed three 14.5” planks  side by side and positioned the bottom row of the crate on top, pushing down.

Using a pencil, we marked 1”, 3”, 5”, 7”, and 9” at ½” from the bottom on the short wooden planks for screw placement. Zoe then drilled pilot holes with a ⅛” drill bit and countersinks with a 9/64” drill bit.

After sanding all four vertical columns with a 120 grit sandpaper, Zoe 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. I 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, I drilled two holes on the longer side for increased support.

For the final row, we decided to add a curved handle. I 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, I 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, I applied the 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.

We now have a crate that we can store our ENGI projects in for the rest of the semester! I think Zoe and I learned a lot about how to construct a functional item out of pieces of wood, as well as how to manage various tasks, including screw placements, sanding, routing, and staining, over multiple days and busy schedules. In the future, I might consider getting higher quality wood that doesn’t splinter and has fewer imperfections, and adding more embellishment to the crate!

 

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