How to Build a Crate

Planning

Sketch out your desired dimensions of the crate in advance. You need to know how big your crate is going to be in order to make the cuts perfectly. You can make any size crate you want, so long as you ensure that the two ends are the same size, and your slats between the ends are the same length. For this lesson, the crate will have the following dimensions (using 1/2" thick planks -- yours may vary slightly). Height: 9-1/2" Length: 16" Width: 12"

Buy your wooden planks. They should be roughly 1/2" to 3/4" thick, depending on your preferences. You'll want solid, untreated softwood, though the exact kind doesn't matter much -- you could easily use scraps or wood from old pallets. Pine and cedar are generally your best budget buys. As for the lengths and widths, you should procure: Six feet of 4-3/4"-wide planks for the ends. Twenty feet of 2-1/4"-wide planks for the slats on the side and bottom. You can adjust this width depending on how big you want the spaces on the side of the crate to be. You can have lots of thinner slats or fewer wider ones.

Cut your wood to the dimensions of your box, plus 1". Unless your hardware store will automatically cut your wood for you, it's time to get the saw going. The best way to get perfect, even cuts is to make a rough cut in each piece first, leaving it 1/8" longer than it should be. Then bunch 4 of these rough cuts pieces of wood together, holding the stack together with tape. You can then cut all the pieces at the same time to get identical lengths. The Ends (4-3/4"-width): You want each board to be 12-1/2" long. There should be 4. The Slats (2-1/4"-width):' You want each slat to be 18" long. There should be 13.

Sand the wood down on all sides. Make sure that all the planks are smooth on all sides. Remember, these specifications are for a 16x12x9.5" crate. After sanding, double-check all of your cuts to make sure you have the right amount of wood. Four 12-1/2" x 4-3/4" planks for the ends. Two of the pieces will be joined together to form each end. Thirteen or more 18" x 2-1/4" planks for the slats on the side and bottom.

Alternatively, use a single piece of wood for the two ends. For a quicker, easier crate, simply cut a piece of plywood or other wider wood right into the size of your ends (here, 12-1/2" x 9-1/2"). It will look less professional, but it will work fine as a crate. You can also use uneven slats of wood if you're using wood scraps or junk pieces -- they just need to be an even length. However, for a professional crate you should cut even slats.

Building the Ends

Dry fit two of the wider boards together along the long side. Take two of your four wider boards and place them together along the long edge. You'll end up with a square 9-1/2" wide, 12-1/2" long. Do this try run to make sure the cuts are even so that the boards come together to form an even rectangle. Repeat with the other two boards. These wider planks will be used to create your ends.

Determine how you're going to adhere the two boards. Building this crate requires that you to adhere the two boards to make the ends. You have several options, including: Biscuit joints. The remainder of the tutorial will be using biscuit joints. Dowels Wood glue. Know, however, that this will not make a very strong box.

With the wood pressed together, use a pencil to mark three spots for dowels or biscuit joints. Mark where you're going to adhere the boxes together on both blanks. For this tutorial, you'll use biscuit joints, though you can use any method you're comfortable with. Make sure you have three wooden biscuits as well as a biscuit drill. Three biscuit joiners for each end should be more than enough. If you're in a pinch, two will do.

Use your biscuit joint drill to make notches at each mark. Like up the drill with your pencil marks and make a clean, quick cut with the drill. Repeat for the other 5 marks.

Apply wood glue to all three biscuit holes on one of the planks. One solid line of glue along the entire edge should be fine.

Insert a biscuit into each hole and firmly push it into place. Make sure each biscuit is snug inside the hole.

Add a little more glue to the top of each biscuit, then attach the two boards together. Simply slot the biscuits into the slots on the other piece. Let the wood glue dry and your ends are finished. Use a rubber mallet to hammer the ends gently, but firmly, together. For the cleanest results, use a set of clamps to hold the two boards together as the wood glue dries.

Optional -- add handles to the ends. Now that the ends of the crate are finished, you can decorate them or add handles. You have several options: Using a table drill with a wide 1-2" drill bit, "punch" holes into each end to make a handle. Simply drill 3-4 holes in a small line to cut a handle in the wood. Using a power drill and some small screws, install two metal handles, like those found on cabinets, into the ends. If adding these handles, wait until the end to install them, as you'll need to lay the box down flush to the ground to finish it.

Putting the Crate Together

Turn the ends upside down so that they are resting on their top edge. The handles, if you added them, will be on the bench. You want the other long edge (12-1/2") facing upwards. Lay 4-5 of the slats on top and adjust the ends so that they are the right distance away. The ends of the slats should be flush with the outside edges of the end pieces.

Place a line of wood glue on each end of the slat and attach it to the ends. This will make up the bottom of your crate. Start with the slat closest to the end so that you're making the corner of the box first.

Use 1" brad nails to firmly adhere the slat to the end. The glue is there to help you get the slat in position and keep it in place as you hammer. You'll need nails to make the crate sturdy. Thin, 1" brad nails work well. Two in each end of each slat should do it. If you don't want to use nails, a thin screw or heavy-duty wood glue may also work.

Add four more slats to the bottom of the crate. Add a little glue, adhere the slat, then nail it in. Start with the other end to make the other corner, then work inward. You should have five slats total on the bottom of the crate.

Repeat the process on each side to finish the crate. Use your last eight slats to finish the crate up. Turn it on its side and attach four slats to each side, spacing them however you'd like. When you're done, let the wood-glue dry overnight.

Optional-- Stain and finish your crate. If you want a professional looking crate, get some stain out or paint the sides. You could use a wood burning kit to etch a design in as well. No matter how you choose to decorate your crate, make sure you wait a day for the glue to dry and the crate to settle before proceeding.