Introduction: Wooden Crate With Lid
Before I truly figured out Kickstarter, I didn't realize that "add-ons" were something you could get by just adding more money to the pledge. So when I kicked (? can we make that official?) a project for a Kubb set, I didn't get the carry tote bag.
But that's ok! It gave me the chance to build this box!
The set fits inside a 12"x12"x6" sized space, with a bit of room on the 6" measurement. So I decided to go the next size up on the Fun fact: that's also the size of the large USPS flat rate shipping box. So if you can fit it in there, it will fit in here. I wanted the box to have handles and a lid to keep out most big things, and for easier carrying. 12"x12" wood can get heavy after awhile.
End result: 1 lidded box
Outside dimensions: 13.5x13.5x7.34
Inside dimensions: 12x12x7
Step 1: Gather Materials
For this project you'll need
1 1"x8"x6' wood board. Get a relatively straight piece & you can get whatever wood suits your fancy. I used soft wood.
1 1/4"x2'x4' plywood sheet. Try to get this as flat as possible; this is the bottom and lid of your box!
Nails: 1" - 1 1/4". You could use screws if you're working with a hardwood
Hammer or drill
Miter saw, chop saw, circular saw, or jigsaw -> whatever you need to get the boards in pieces. Some shops even cut the wood into the right lengths for you
Router with 1/4" straight cut bit or table saw with dado blade 1/4"
Time to complete: an afternoon with some spare daylight on the side
Step 2: Create Side Board & Create Groove
You've got 2 options for how to assemble your box: you can make a square box with 2 edges overlapping, or take the basic box design & add some extra decorative features to make it more "crate like". (the one I'll be building is definitely more crate-like). For the crate-like box, cut the 1"x8" to 55. If you're making a standard square, cut the 1"x8" to 51 1/2". There's some extra length included for the width of your saw blade just in case.
Optionally, if you're going for the crate-style, you should cut the supports for the sides now too. Cut 4, 1" pieces.
Next we're going to cut the entire slot for the bottom of the box in one pass. That way, it's easier to line everything up when putting in the bottom. Take a 1/4" router bit and measure up about 1/2" from the bottom edge of the board. Adjust the height of your router to be 1/4". Line your router up to cut with this marked as the center, and route/cut the entire length of the board.
Step 3: Cut Sides
Let's cut those sides!
For the crate: 15" + 15" + 12" + 12"
For the square: 13 1/2" + 13 1/2" + 12" + 12"
Now, check to make sure the box is acting box-like! Basically make sure that everything lines up, straight lines were cut, the routed edge lines up, that sort of thing. Remove any extra pieces you have.
Step 4: Cut Base & Lid
The base for the plywood sheet will be just slightly larger than the inside of the box since it'll rest right inside that grooved area. The cut is 1/4" so our plywood dimensions are 12 1/2" x 12 1/2". Cut from the plywood sheet.
We want the lid to cover the entirety of the top, so we'll cut a 12 3/4" x 12 3"4" square. We'll be doing more with this later, so put over to the side. Because we'll want the lid to fit into the box & not slip off, we're also going to build a lip into the lid.
Whew, it's good to get the cutting done.
Step 5: Build Basic Box
So now we have all our pieces for the bottom, let's get this thing together! Form 3 sides of the box, overlapping the end of the short side with the long sides. Drop the base into the slot formed by all the grooves of the 3 sides. Place the other short side over the end of the base. Make sure all the sides fit tight; file or cut the base to get the sides all square.
I attached the second picture again so you could see the base dropping into the slotted groove.
Once you're happy with the fit: glue, clamp, and let dry.
Step 6: Nail the Sides of the Box Together
Wood glue is incredibly strong, but we're going to reinforce the sides with some nails.
For the crate: on the long sides, hammer small triangles to both the short side and the support brace at the top and bottom of each side. Nail the support brace to the short side of the crate, careful to not drive through the other nails. They don't have to be in the same spot if you're going for a rustic feel on the box.
For the box, drive 5 roughly evenly spaced nails through the long side into the short one.
Step 7: Drill Holes for Lid
On the lid: make marks for the holes, 2" up from the bottom, 5 1/2 inches from the left and right sides. Drill a 3/8" or 1/2" hole. Sand clean, and soften edges around the hole.
On the short sides: make marks for the holes, 1 1/2" down from the top, 4 1/3" from the sides.
Step 8: Attach Handles
Cut 3 pieces of rope. Knot at one side. Braid or twist the pieces together without tying the other end.
Thread the rope out to in on the side of the box, up through the bottom of one hole in the lid, down through the other hole, and in to out the other hole on the side of the box. Tie the rope
Repeat for other handle.
Step 9: Finishing Touches!
Now that you're done, you can sand the edge of the lid, and personalize it! Some wood burning is good for permanently marking this as your awesomely constructed box. Put in the game set and get ready for some outdoor fun.