Crate Building Guide
Materials Needed
- Standard 40" x 48" pallet
- Sheet of 3/4" plywood for base--no substitues
- Plywood or particle board for sides and top
- 2x4s for interior frame and bracing pieces
- Screws
- Screw gun
- Saw (or precut lumber from Home Depot, Lowe's or your local lumber yard)
Step 1: Start with a Standard Pallet
- Use a Standard 40" x 48" pallet.
- Lay it flat on the floor and securely screw a sheet of 3/4" plywood to the top.
- Note: Do not use MDF or particle board for the base. They are not strong enough.
- Alternatively, if you don't have access to a standard pallet, you can build skids on the bottom of your plywood base..
- Cut 6 pieces of 2x4 to the width of the crate.
- Screw them together in sets of two.
- Attach one set of "legs" to each end and one to the middle.
- Note that standard pallet jacks are 27" wide from outside to outside and they will need to fit into the openings you've created to move the crate around during transport.
Step 2: Frame the Base Perimeter
- Fasten 2x4 footing pieces just inside the outer edge of the base.
- These will serve as anchor points for attaching the crate walls.
Step 3: Place and Stabilize the Engine
- Carefully position your engine upright on the center of the pallet.
- Use additional 2x4 pieces to brace around the engine base, preventing it from sliding.
Step 4: Cut and Attach the Walls
- Cut four wall panels from 1/2" plywood.
- Note: Particle board is acceptable for use as wall material
- Attach each panel using 2x4s in the corners for structural support.
Step 5: Box in the Engine for Transport
- Cut additional 2x4s to fit snugly around the engine.
- Anchor these to the side walls to prevent the engine from shifting in transit.
Step 6: Reinforce the Top Perimeter
- Attach 2x4s along the inside top edge of the wall panels.
- These will provide a sturdy surface to fasten the crate's top panel.
Step 7: Secure the Top Panel
- Once everything is braced and sturdy, screw the top panel onto the crate using the 2x4 frame underneath for support.
- Your engine is now ready to transport!
