How To Build the Perfect Crate for Your Shipping Needs

You can always go to a packing center to pick up a shipping crate. The shipping service can also provide crates. While this is an easy and convenient solution, it’s also expensive. A small cardboard box can run you $10 or more—now, just imagine what you’ll pay for a large crate.

But thankfully for you, there’s a much more cost-effective solution available: you can build a shipping crate yourself. Not sure how to get started? Here are some tips on crafting the perfect crate for your shipping needs.

Gather Your Materials and Tools

In most cases, you probably already have all of the necessary tools hanging in your garage or a storage shed nearby. A trip to a home improvement store is often necessary to get the extra materials you need.

So, what tools will you need? Start by getting out your saws: you’ll need chop and table saws, although you can also get by with a panel and bandsaw. You’ll use the saws to cut the 2×4 boards down to the appropriate size.

You’ll also need a drill: cordless drills often work best since your movements aren’t limited by the length of the electrical cord. To hold the boards together, you’ll also need screws. Screws measuring 2.5” and 1¼” work best on this type of project.

Here’s a list of the materials you’ll need to craft a shipping crate. When it comes to choosing the boards, think about the size of the crate.

• 2×4 boards
• 4×4 boards
• Inexpensive sheet of plywood for the base and sides of the crate. Stay away from particle board since this material won’t hold up in damp conditions.
• A sheet of foam insulation

Remember, crate size will determine board length and width. If you only need a small crate, you may be able to save some money and use scrap wood instead of more pricey 2x4s.

Create a Plan

You already have a general idea of the crate’s size. This is based on the item you’re shipping. You want the crate to be large enough to hold the item but not too big. You don’t want your belongings sliding around inside the crate during shipping.

Go ahead and sketch out the crate’s general desig; you don’t need to be an architect to draw a diagram of the crate. Make sure to mark the areas where the screws go and the board size, as this will come in handy as you’re building your shipping crate.

Start with the Base

Most people find it easier to attach the boards for the sides to the base, and building out the sides first means having to lift them onto the base. Depending on the shipping crate’s size, this may require using a forklift or pallet jack, and these are tools not commonly found in most homeowners’ garages. You’ll need to rent one of these machines, and prices can be expensive.

The base should be wide and long enough to comfortably accommodate the item, so use a measuring tape to ensure the dimensions are right. If necessary, cut the particle board down to the appropriate size. Next, attach a layer of protective foam, as this will help protect your item during shipping. For example, if the crate is dropped or set down heavily.

To keep the foam in place, attach it to the base with a few of the shorter screws. One at each corner is usually enough to hold the foam lining in place.

Build the Sides

Okay, your crate has four sides and they all may not be the same length. To help make the process a little easier, it’s a good idea to label the sides A, B, C, and D. 

Sides A and C should be the same length, and the same applies to C and D. This is when you want to measure carefully, including the base. You don’t want one of the sides hanging over the base or being too short to cover the ends.

Use your saws to cut the boards to size, and a good tip here is to mark the boards where you want to cut; after cutting the boards, you can start nailing them together. You’re going to nail the boards to the top, bottom, and sides of a single piece of plywood. The boards are basically serving as a supportive frame around the plywood sides.

Finally, Build the Top and Ship Your Crate

If your measurements are correct, you should have enough foam and particle board left over for the top. From there, lay down the foam first and attach it to the top. With the foam side down, nail the top to the four corners.

Now you’re ready to place the item in your crate and call the shipping company to come pick it up, or you can also drop your crate off at the shipping company. This can save a little on shipping and delivery fees.