See how to add the 1×2 rails to the top and bottom plywood of our crate and why I did not pre-cut or even use a tape measure on them in Part 2 of this build series.
See the Whole Series
This 5 part series takes you step-by-step through building this crate.
See the whole build series in order here
In Part 1 we:
- took our measurements
- gathered our materials and tools
- cut the plywood for the top and bottom of our crate
In Part 2 today you’ll see:
- how I added the 1×2 rails to those top and bottom plywood pieces
- why I did not pre-cut the wood beforehand
- why I didn’t use a tape measure on any of it
- how I securely attached the rails with glue and brad nails
Video
Transcript highlights and images are below the video too!
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Materials List for Part 2
See all of the lumber you will need for this part of the project.
(We’ll add the door rails later.)
The full lumber list is in Part 1
1×2 Rails
Tools and Supplies List for Part 2
See tools and supplies you will need for this part of the project.
The full list for the whole project is in Part 1
Hand Tools and Supplies
Power Tools
Safety Gear
What We’re Building Today
Here’s what a completed top/bottom looks like when the rails have been added to the plywood.
Measuring the 1x2s
1x2s are notorious for warping and bowing.
So I didn’t use a tape measure to mark for the cut on these.
I literally laid it on the plywood and marked it for the cut.
A nice Irwin clamp helped hold it in place for me.
This is specifically why I made my workbench with a lip on the top edge – to give me room to clamp.
Glue the Rail
Once you check the fit and make the cut it’s time to attach the rail.
I like using Titebond III for just about everything. I just think it has a superior hold.
Brad Nail the Rail
The glue is what will actually hold the rail to the plywood over the long-term.
But, to keep the rail in place while the glue dries, instead of just clamping everything, a few brad nails will allow us to continue to build the top.
I used a couple of Irwin clamps to hold the glued rail into place.
NOTE: Place the clamps about 2” from each end, so you can tack a nail into the ends without having to move the clamps.
And then I used my brad nailer, with 1” nails to tack it into position from underneath.
NOTE: Brad nailers shoot those nails out at high velocity.
Never put your hands or face directly above where the nails are being inserted.
Flip and Repeat
Next I flipped the plywood around to add the second short rail.
Install Long, Inside Rails
Since I went end-to-end with the first two short rails, that meant the two long rails would have to sit inside them.
I just laid the 1×2 butt end to the short rail on one side.
And then I made a mark on the inside of the other butt end, dragging my pencil along the short rail as the references.
NOTE: Due to the angle of laying in the long rail this way, you may want to make your cut just a smidge outside your mark for a tighter fit.
Glue, Nail, and Repeat
Attach your first long rail.
Then measure, mark, cut, and attach the second long rail.
All Done with This One
And there you have it!!
Make another just like it and you’ll have your top and bottom of the crate done and ready for the next step.
Next
Be sure to see Part 3 where we’ll add the upright supports.
If you’re enjoying this build, please subscribe to this YouTube channel.
And I’ll see you in the shop.
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