![]() ![]() The base will need to be fully framed with 2x4's to make sure it can support the weight all the way around. The dimensions of the base match the dimensions of the sculpture, adding 1/2" perimeter to allow space for foam on all sides. Make sure the spacing is at least 3.5" off the ground! (Note the dimensions of a pallet jack for reference). Build the box and attach it to a stock pallet (shown in the illustration.) Or, I prefer to build the risers as part of the base (using a 4x4 on end as the riser). If you think your crate will be heavy and/or large, you should definitely start with a pallet base so that it can be fork-lifed or pallet jacked. Once you figure out all the measurements, you can cut the parts to length as you go. A bandsaw is the easiest and safest way to do this, or a table saw works too. It will still be plenty strong for a crate. To save some weight and to avoid over-building, I recommend ripping down the 2x4 in half (that is making two 1.75" wide instead of using a full 3.5" width) to make the frames for the sides. All sides screw through the 2x4 frame into the pallet base with the 2.5" screws along the bottom edge. Sides B and D are longer so they overlap and screw into sides A and C. Note that the sides are paired - A and C are the same size and flush to one edge of the base. There will probably be some adjustments to measurements as you go, but it helps to have a list - see the example included in the drawing above. I suggest you make a cut list of parts with dimension of all parts (top, bottom, sides A/C, B/D). Start by measuring the overall dimensions of the thing you are shipping, and make sure you account for the 1/2" thick foam on all sides. The diagram I drew has variable dimensions (X x Y x Z) because these measurements depend on the object you are crating. You can reinforce the corners with strips of OSB or scrap plywood instead.īefore you cut anything - figure out exactly how big your crate needs to be. (For reference, my crate ended up being 40" x 46" x 26" high, and I used two sheets each of OSB and Foam, and probably four 8 foot 2x4s).įor smaller crates that are lightweight and won't be fork-lifed, a 2x4 frame is probably overkill. The amount of materials you need will depend on the size of your crate. ![]() ** Optional - Bandsaw (for ripping 2x4s in half along their length) Table Saw or Panel Saw (for cutting down sheet good) Screws (I like two sizes, some at 2.5" length and some at 1 1/4" length) 2 Cordless drills (an impact driver for driving screws and a regular drill for pre-drilling holes) 1/2" Foam insulator sheet (I like the lavender stuff, but the white/aluminum stuff works okay too). I paid less than $20 for a full sheet (48" x 96") of OSB. 1/2" OSB or similar inexpensive plywood product (not MDF or Particle board - they won't hold up in wet weather). 2x4s (note, the actual dimension is 1.5" x 3.5") You can buy all these things at Home Depot or Lowes. ![]()
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