Cost: I spent $63 in materials in order to make 9 of these and I did have some material leftover. I was 1/8" away from having enough birch to make a 10th crate due to a miscalculation.
Tips: I used 3/4" Birch plywood (furniture grade) but you could probably get away with 3/8" or 1/2". Use a fine tooth sawblade made for cutting plywood and you will get much nicer cuts.
Dimensions: Dividers are 1/8" Masonite 4" tall with 2-1/2"X2-1/2" openings. (3 pcs. 4"X16" and 5 pcs. 4"X10-1/2" with sawcuts 2" deep, equally spaced to make 2-1/2" spaces)
Bottom: 3/16" Masonite 16-3/4" X 11-1/4"
Sides: 2 pcs. 6"X17-1/2" and 2 pcs. 6"X12" with 1/2" X 3/4" box joints on both ends and a 3/16"X3/8" deep groove on all insides 1/2" up from bottom to accept 3/16" masonite bottom.
Glue: Apply with brush to all box joints, bottom dado groove and assemble. After glue is dry, I put 1/4"R round over bit in router and relieved all sharp corners. Finish sand with orbital sander and you're done.
Make a custom stencil, cut out letters with an exacto blade and spray paint from a minimum of 12" from crate.
Handcrafting
these crates gives you a similar feeling in the
end as making beer except they last longer.
