Step by Step Instructions: How to Make a Wood Crate

This is how you build a

wood crate

with a 48 x 48 x 48-inch crate with an 8-inch wooden pallet using 1/2-inch plywood for the sides, top, and bottom of the crate, and 2 x 6 pine for the edges and corners. Crates like this are structurally more robust than wooden boxes and as such are used primarily for shipping heavy loads by truck and as a rule must be fork liftable.

learn how to make plywood crates with an integrated pallet

What you will Need (materials)

  • 2 sheets of ½ inch plywood for the sides, top and bottom
  • 1 sheet of ¾ inch plywood for the top of the box
  • 4 eight-foot lengths of 2 x 6 construction grade spruce for the edges
  • 4 ten-foot lengths of 2 x 6 construction grade spruce for the edges
  • 1 twelve-foot lengths of 4 x 6 construction grade fir for the vertical pallet supports
  • 4 twelve-foot lengths of 1 x 4 construction grade spruce for the top pallet slats
  • 4 twelve-foot lengths of 1 x 4 construction grade spruce for the bottom pallet slats
  • 1 box of 2-inch Robertson wood screws
  • 1 box of 1.5-inch Robertson wood screws
  • 1 box of 1.5-inch finishing nails

Tools

  • Electric power saw
  • Drill with compatible bits
  • Hammer
  • Measuring tape
  • Marking pencil
  • Rafter square

Steps

  • Step 1: Clear your workspace so you have enough room to build the crate.
  • Step 2: Begin making the pallet by cutting 4 x 6 into 48-inch lengths and arranging them on the floor short side up spaced evenly apart so the center piece is 24 inches from edge to center.
  • Step 3: Cut each of the 1 x 6 into 48-inch lengths and place 12 boards on top of the 3 up right 4 x 6’s. Use the 1.5 Robertson screws to fasten each of the boards to the frame; 2 screws per board where it crosses the 4 x 6. Counter sink each of the screws slightly. After fastening the first board, use the edge of another board to space the second board from the first board and then fasten the second board leaving about a ¾ inch gap all along the board. Repeat until all 10 boards are fastened to the pallet frame.
  • Step 4: Flip the frame upside down and fasten the remaining 12 boards to the frame to complete the pallet.
  • Step 5: Cut 2 of the 2 x 6 spruce fifty-one inches and using the 2.5-inch Robertson screws, fasten the board on its flat side to each of the ends of the three 4 x 6 pallet frame boards. The 2 x 6 board should hang 1.5 inches past each side of the pallet and run parallel to the floor leaving a 3-inch gap between the bottom edge of the 2 x 6 and the top edge of the bottom 1 x 6 pallet boards to make room for insertion of the forks of a forklift.
  • Step 6: Cut 2 of the 2 x 6 spruce forty-eight inches and again using the Roberson 2.5-inch screws, fasten the board on its flat side between the fastened 2 x 6 boards so the insertion of the but end of the 48 -inch board onto the overhanging end of the 51-inch board creates a corner joint that is flush. Two 2.5-inch Robertson screws should be used to fasten each of the corner joints.
  • Step 7: Cut a ½ inch plywood in half and place a long edge of the plywood sheet so it nestles next to the 48-inch base board fastened to the pallet and screw it in place using the 1.5-inch Robertson screws. Repeat for the opposing side.
  • Step 8: Cut the other ½ plywood so it measured 47 x 48 inches and insert he short side in between the 2 attached sheets and screw them in place using the 1/5-inch Robertson screws.
  • Step 9: fasten the 4 vertical edges of the plywood box using the 1.5-inch finishing nails.
  • Step 10: Cut 2 of the 2 x 6 spruce fifty-one inches and using the 2.5-inch Robertson screws, fasten the board on its flat side to the top edge of one side of the plywood box so the top edge of the 2 x 6 and the plywood are flush all along the edge. Fasten the other 2 x 6 to the opposing side of the box, also flush with the top edge. The 2 x 6 board should hang 1.5 inches past each side of the box.
  • Step 11: Cut 2 of the 2 x 6 into forty-eight-inch pieces and again using the Roberson 2.5-inch screws, fasten the board on its flat side between the fastened 2 x 6 top edge boards so the insertion of the but end of the 48 -inch board onto the overhanging end of the 51-inch board creates a corner joint that is flush. Two 2.5-inch Robertson screws should be used to fasten each of the corner joints.
  • Step 12: Fill the interior of the crate with goods. Make sure you include a packing list or bill of lading.
  • Step 13: Cut a sheet of plywood 48 x 48 inches for the top of the box. Fasten the top sheet to the 2 x 6 surround using the 1.5-inch Robertson screws.
  • Step 14: Cut 2 of the 2 x 6 into fifty-one-inch pieces and fasten them flat to the top of the box flush with the outside edge where each of the 48-inch 2 x 6 are fastened on edge and screw the two together using the 2.5-inch Robertson screws.
  • Step 15: Cut the remaining 2 of the 2 x 6 into forty-eight-inch pieces and fasten them flat to the top of the box so the outside edge is flush where each of the 51-inch 2 x 6 are fastened on edge to the box and screw the two together using the 2.5-inch Robertson screws.
  • Step 16: The crate is ready for shipping.

Definitions

Flush: In woodworking, the term "flush" refers to making the surface of two different pieces of wood level or even with each other. This is often achieved by carefully joining the wood so that there are no steps or gaps at the junction where the two pieces meet. The goal is to create a smooth, seamless surface, where the transition between the two pieces of wood is barely noticeable.

Robertson: The Robertson screw, also known as a square drive or square recess screw, is a type of screw with a square-shaped indentation in the head. This design was invented in 1908 by P.L. Robertson, a Canadian. The Robertson screw is notable for its self-centering feature square hole, which reduces the chance of the screwdriver slipping out, and allows for greater torque to be applied compared to other types of screw heads like the Phillips or flathead. This design makes it particularly popular in woodworking and in situations where a more secure grip is needed. The screw's recess provides a snug fit for the screwdriver, which is especially useful for one-handed operation or in hard-to-reach places.

Wood Pallet: A wood pallet is a flat transport structure that supports goods in a stable fashion while being lifted by a forklift, pallet jack, front loader, work saver, or other jacking device. It is typically made of wood, although versions made from plastic, metal, and recycled materials are also available. Wood pallets are the most common type and are widely used in the shipping and warehousing industries to move large loads or to store goods in stacks. The design of a wood pallet usually consists of a series of wooden slats or blocks arranged in a specific pattern, creating a sturdy platform capable of supporting heavy weights. The spaces between the slats allow forklifts and other lifting devices to easily insert their forks for lifting, moving, and stacking. Pallets are essential for efficient storage and transportation of goods, enabling the easy handling of large quantities of products and materials.

Article posted, Mar 02