How to make a classic wooden crate. Easy + advanced versions.

Today I've got two versions of the
classic wooden crate to make the easy version you'll need four 1 by threes a
miter saw clamps jigsaw a drill and a small workspace I'll be building the
whole thing on my basic mobile workbench by the way if you haven't built this
space-saving workbench yet be sure to download free plans at it's the perfect first project if you've never built anything
in your life no table saw needed the advanced crate has a more traditional
look it's a lighter weight with thinner sides and bottom slats you'll need a
table saw to build this one but only three one by threes and of course I've
got free plans for both crates down in the description
normally I would advise you never to cut all the pieces to a project at the same
time but in this case there's only two different sized boards that you'll need
and it just makes sense to cut them all at once the home center had some really
crappy boards to choose from this time check out this one there's a lot of
warped boards luckily there's enough kind of scrap built into this
project that I'll be able to just cut that part off and use the rest of it
I've attached an auxilary fence just a board to my miter saw so it gives me a
little extra room over here where I can attach a stop block and I've made a
couple of marks where I'm going to be cross cutting the boards to length now I can slide this stop block in for the
shorter pieces the next thing I want to do is edge join
the shorter boards together to make those end panels so what I'm going to do is
put a bead of glue along three of these and spread it thin this is tight bond 2
yellow wood glue I'm using and I'll just push these together just make sure
they're all flush yeah if you get these too tight these
boards will just spring apart the whole point of the clamps is just to keep the
boards from moving while the glue sets I'm gonna use these clamping cauls these
are just boards that I've put packing tape on so that the glue doesn't stick
and this'll sandwich these boards together this way to keep them flat and
again if you've over tightened these pipe clamps it'll be really hard to
flatten these boards out using these F clamps and that looks pretty flat and
the ends are still flush okay I'm going to let these dry for at least
an hour I got a late start this afternoon so I'm just gonna call it a
day and come back in the morning for these here it is the next day you can
tell it's the next day because I have a different shirt on yep nothing beats
the next day if you have a jigsaw and want to make finger holes for your crate
find a cap or some other round object that you can use to create some curves something like that now drill an entry
point for your jigsaw you want to sand down the inside edges
of these holes so they're not so sharp assembling this is simple I'm going to
start by attaching the bottom slats with glue and screws and that can get a
little tricky because it's a little wobbly right now so what I'm gonna do is
clamp a couple of pieces on to the bottom here and this also helped me just
keep it squared up so of course I just want to make sure that the ends of these
boards are flush with the sides to prevent the ends of these boards from
splitting I'm going to drill pilot holes before driving the screws in place but I didn't quite get that center one
straight that's what gives this crate character if you wanted perfection go get a CNC machine I'm not putting a screw in right here because it might run
into that screw so I've offset it a little bit honestly I love the look of
the screws in this crate it just screams sturdy that one split a little bit but
it's not going to affect the strength of this crate and just gives it a little
extra rustic charm so of course you could paint or stain or
finish this however you like but actually I think crates look best when
they're just left unfinished using the table saw is going to give me a lot more
precision on the advanced version of the crate
I'll start by cross cutting out all of the pieces for the end panels just like
I did on the easy version only this time I'm gonna cut them all just a little bit
longer than their final size I'll get a nicer seam when I edge join all of these
together if I shave a little bit off of each edge for that I'll use my rip fence gluing these together is going to be
the same as before only this time it's actually going to be a little bit easier
because I don't have to worry about getting all of the ends flush and while those are drying I can get
started on the slats the slats on this crate are gonna be a little narrower so
I'll rip these boards down to their widths first I've slid over my rip fence
so that I'll be able to resaw these boards right down the middle so I'll
have two equal thickness pieces I've set up a featherboard to keep my stock
pressed against my rip fence as I'm passing it through the blade I've also
added on an additional block on my gripper so that it's up high enough I
can keep it in place in front on this side of the blade to help keep it
pressed down as the stock is running through and finally when the board gets
towards the end of the cut I'll need a way to push it through I can't use the
gripper on this part because the featherboard is here so I'm gonna use
this scrap that I used to test the thickness of the board as a push
stick to push it on through resawing lumber on a table saw is an advanced
level procedure if you feel the least bit uncomfortable about this setup don't
do it of course if you have a bandsaw you could do the resawing on it or if
you have a planer you could plane the wood down thinner or you could just buy
thinner stock from the lumberyard or even use quarter-inch plywood lastly I'll crosscut these two links now
I can square up those end panels to make the handles on this one I'm going to
start by drilling two holes using a Forstner bit instead of sanding these handles I'm
going to use a quarter inch roundover bit on my router to ease over the sharp
edges instead of screws on this one I'm going
to use glue and inch-and-a-quarter finishing nails the screws are just a
little bit too aggressive on this thin wood and it's just too easy to split

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