Building a shipping crate
Having built this crazy pantorouter tradeshow display, I had to get it shipped. And for that, I made a shipping crate.
At left, I already have the pieces for the box cut out. I found the plywood by a dumpster a year ago. No doubt it was part of a shipping crate originally. It wasn't very good plywood, though I turned the nicest of the pieces into the backer for the tool holders.
There are metal strips that can be nailed to the outside for reinforcement, but I couldn't be bothered to figure out where one could obtain such strips. Easier to just use what I have at hand. (I'm only mentioning this to avoid people emailing me to tell me about it.)
The strips will form squares along the large sides of the box. For extra sturdiness, I joined the corners with box joints using my trusty old box joint jig. I stacked two 7 1/4" blades for a wider kerf, so I could hog out the 1/4" in just two passes. With four workpieces in the jig at once, It took 20 seconds to cut the joints in all four.
To make it go faster, I stacked two saw blades in the saw to make a wider kerf. Then, to hog out the 1/4" slot, I made two cuts, with the second cut made backwards as I pulled the sled back towards me. The red piece of tape on the 48 tooth gear marks the crank position for the second cut. More on cutting box joints without a dado blade
Putting the piece on. I figured I might as well clamp it on to make sure I had good contact. When driving nails with a hammer, the nails really pull the pieces together. But air nailing doesn't help in this regard.
My long reach clamps really come in handy to push the joints together before nailing.
But the nails were all further from the edge than the cut. The bevel makes the edges of the box nice to handle.
Thanks to the box jointed frame it ended up quite ridgid even without the lid on. I'm thinking, a box like this could make a good frame for a dresser if made using better plywood. And just 1/4" plywood would be sufficient.
I figured it would be good to make sure the lid goes on the same way each time, so that the screws go in the same holes. I added a tab to one of the cleats and a notch to the frame. Now the lid only fits on one way!
On receiving it, Mac made a short video about it, click play button at right to play it.
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