How to Build a Crate

Sometimes you need to ship an oversize items you don't have boxes or pre-made crates for. IF so, you can build a crate yourself. Follow these steps to build and pack a shipping crate.

Difficulty:

Moderate

Instructions

Things You'll Need

• Plywood
• Strips of lumber (such as pine) 2 inches wide by 1 inch thick
• Power drill
• Screws
• Measuring tape
• Pencil
• Soft foam or bubble wrap
• Rigid foam
• Foam peanuts or newspaper

Framing

1. Measure the items you want to pack. Allow for some extra room so that the contents will fit inside your crate.

2. Write down the measurements for your crate. This will be a simple rectangular or square box construction. These measurements will determine how much plywood you will need and how long your wood strips will be.

3. Cut the lid, base, sides and ends out of plywood.

4. Attach 1-inch thick by 2-inch wide strips onto the two sides of the plywood pieces with screws. The strips should be almost as long as the sides of the plywood. Inset the strips by the thickness of the plywood.

5. Screw a 1 inch by 2 inch strip onto each end of the lid and base panels. Inset those strips the thickness of the plywood plus the thickness of the strip at each end.

Assembly

1. Attach one of the end panels to the base panel.

2. Position the piece on the lip that is sticking out beyond the strip. It should fit flush next to the strip.

3. Put one of the side panels on. Screw it to the base and end panel. Put the other end on and the other side. Now you have the box assembled and just need to put the lid on.

Packing

1. Decide how you are going to pack the items you are shipping.

2. Wrap the items with soft foam or bubble wrap.

3. Measure and fit the rigid foam in the box and cut the foam to fit the object.

4. Use foam peanuts or crushed newspaper for further protection.

Tips & Warnings

• Snap photographs of the contents before closing the crate in case you need it for insurance.

• If you are shipping by air, remember that you might have to open the crate for inspection.

• Purchase insurance; hopefully you won't need it.

• If the plywood splits, use the power drill to make the holes and put the screws in.

• Make sure all the contents are inside before closing the crate.

• Don't forget to mark the crate with the appropriate messages. Write directions "Up" or "Down" and use arrows. If the contents are fragile, mark that on the crate.