For Christmas Roxie got a fantastic set of
Melissa & Doug Blocks
. They come neatly packed in a wooden crate with handles.
The problem is that the crate, when full, weighs almost 20 pounds. So poor Roxie couldn't even pull the crate out from its storage spot, let alone move it across the room to wherever she wanted to play. This box needed wheels.
I ordered four
swivel casters from Home Depot. Then I took a look at the bottom of the crate to see how best to attach them.
The bottom of the crate seemed pretty flimsy. I could tell that the wood that was used for the bottom panel was much thinner than the wood that was used for the sides of the crate. Roxie already liked to climb into the crate and sit in it, and I was worried that the bottom would eventually crack.
The flimsiness of the bottom was not helped by the fact that it was recessed, leaving a 3/8" gap between the bottom of the crate and the floor.
So the first step was getting a piece of 3/8" plywood and cutting it to fit in that space. Initially I tried to make a paper template before realizing that I should just (duh) measure the sides and use a square to help me trace straight lines to guide my cuts.
I used a handsaw to cut out the plywood rectangle because I want Michelle Obama biceps because we don't own a circular saw. Then I sanded down the edges. I got a LOT of splinters. Sanding plywood sucks.
I used a thin piece of scrap wood to spread wood glue on the bottom of the box and the piece of plywood.
The directions said to clamp the pieces together for at least 30 minutes. I don't have a clamp, but I have some heavy boxes of cat litter.
The plywood was annoyingly still not flush with the edges of the box, so I took all the thin scraps of wood that I had and spread them out on the bottom of the box to make up the difference. Then I glued them down.
I traced the whole box on a piece of 1/4" MDF. This piece was going to cover the entire bottom of the box, reinforcing the base and making it thicker so that I could screw the casters in securely. Then I cut out the MDF rectangle using my trusty handsaw. MDF is
much easier to saw than plywood. And sanding it is downright pleasant. No splinters, just dust!
I glued the MDF to the bottom of the box just like I had done with the plywood, "clamped" it with the cat litter boxes, and left it overnight. (No pictures; they would be pretty boring.)
Then I had to figure out where to place the casters. I decided that they should be placed 3/4" from the edge of the box, and I cut out a quick cardboard template to help me place them.
I used a pencil to mark where the pilot holes for the screws should go.
Then I drilled all the pilot holes. My screws were 3/4" long, so I put a piece of tape on my drill bit at 3/4" so that I didn't accidentally drill through the bottom of the crate. Of course the drill bit broke after I had done 15 of 16 holes. After using pliers to remove the half of the bit stuck in the crate, I finished up the last pilot hole.
Then I had to screw in the 16 screws. I could have used the drill as a power screwdriver to help me, but I wanted those Michelle Obama biceps I am scared of using the drill as a screwdriver. I've had bad experiences in the past with stripped screws and broken-off screw heads.
Then it was done!
I flipped it over and filled it back up with blocks. I couldn't wait to show Roxie.
Naturally, the first thing she wanted to do, once she saw that her crate now rolled around the room, was empty out all the blocks, get in the box and go for a ride.
So we did!
For a simple project, this was not as cheap as I'd hoped it would be.
Cost breakdown:
- 4 casters: $10
- plywood: $6
- MDF: already had
- thin wood scraps: already had
- screws: $3
- wood glue: $3
- Total Cost: $22, with lots of screws, glue and some plywood left over.
But just like
the light table, I got to use my brain and do some problem-solving and Home-Depot-aisle-wandering, and that's worth the 22 bucks to me.
PS - At some point we'll return to our regularly-scheduled home improvement blog. Maybe once it gets warmer.