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New Clone (OSW Staff)
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Discussion Starter #1 (Edited)
Well, after a long wait. I have finally got a crate tutorial for you.

Items needed:
White glue
Xacto knife and hobby saw
Metal Straight edge
Popsicle sticks
Tongue Depressors (TD)
1 Box: 4" deep, 6,1/4" wide and 4,1/2" tall.

First thing to do is make sure the box is squared. If not, you will end up with a crooked mess of a crate.

Remove the top flaps of the box. Leave the bottom alone.
Measure out 12 TD's to the length of your box. Mine turned out to be a touch longer than my TD's but it turnout perfectly. Glue them to the side of the box. Be sure that the box sits flush with your working surface. And glue the TD's flush with the work surface and the bottom of the box. Let the set and them repeat for the other side. Be sure to let the glue set before beginning the next step.
 

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New Clone (OSW Staff)
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Discussion Starter #3
Next, measure and cut 12 more TD to the size of the end of the crate. Be sure to measure flush with the TD's already attached to the box. Glue them in place and again, allow the glue to set.
 

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New Clone (OSW Staff)
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Discussion Starter #4
The edgers of the crate should now look like this.
 

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Discussion Starter #5
Now cut 8 TD's to the height of your crate as it is now. Glue them in place so that they are flush with the bottom of the crate. They should form a sharp corner. Hobby clamps will help in this step as the box you use may have bulging sides. The corner should look like this.
 

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New Clone (OSW Staff)
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Discussion Starter #6
Now take 4 TD's and cut them in half length-wise. These will form the top and bottom frames of the crate sides and ends. Measure and cut to fit them in between the vertical ends. Cut one more TD the same way and measure it to fit as the cross brace. Cut 45 degree angles in the end so it fits into the corners. A regular popsicle stick can be used for the crate ends cross brace.
 

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New Clone (OSW Staff)
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Discussion Starter #7
The Top: You have 2 options for this. It can be permanent or or removable.
Permanent: Just flip the crate overand measure and cut your TD's the same as you would a side. Frame it the same way also.

Removable: Measure out the top of the crate, front to back. Cut 2 TD's to that size. Measure the length of your crate. Set the 2 previously cut TD's at that distance. Take 6 TD's and glue them to the 2 ends.
 

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New Clone (OSW Staff)
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Discussion Starter #10
Now flip the it over and Frame it the same as you would a side. Your crate is almost done and should look like this.
 

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New Clone (OSW Staff)
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Discussion Starter #11
The bottom should be accessable to a 1/6th forklift. So to do this, Measure the bottom of the crate, front to back. Cut 9 popsicle sticks to this length and glue 3 sets of 3 together. Then gluie them to the bottom. The 2 end ones should be about 1/2" away from the edge of the crate. The third just gets placed in the middle.
 

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New Clone (OSW Staff)
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Discussion Starter #12
Voila! Your crate is ready to be decorated and weathered any way you see fit. I hope this tutorial was a use to someone.
 

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Registered
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Wow that is great. I didn't realize you had a cardboard box underneath! Thanks for the great tutorial. I've gotta try this.
 

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Working on the pics thing
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HP: That is a tremendous tutorial!! Excellent work, now I have, yet, another use for popsicle sticks, and even get to add TDs to the list. Thanks!!!
 

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Requiescat In Pace
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Best woodwork class ever.
 
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