Dave suggested that cases would be a good way to store mason jars full of food. At first I thought this was unnecessary, but the more I thought about it, the more I liked the idea. If all your jars won’t fit on shelves, you need someplace else to put things, and placing them in sturdy boxes allows for safe stacking and easy transport. We figured out that an area 16-1/2″ x 16-1/2″ x 7″ would allow for 25 pint jars or 16 quart jars. Filled weight with quart jars would be 33 pounds. I couldn’t get this out of my head until I had a design down, and so this is what I’m sharing:
2 sides:
1/4″ plywood cut 16-1/2″ x 8-1/2″
1×2 (or 3/4″ x 1-1/2″ S4S) cut 16-1/2″
(2) (or 3/4″ x 1-1/2″ S4S) 1×2 cut 7″
front and back:
1/2″ plywood cut 18-1/2″ x 8-1/2″
bottom:
3/4″ plywood cut 16-1/2″ x 16-1/2″
lid:
1/4″ or 1/2″ plywood cut 18-1/2″ x 17-1/2″
(4) 1×2 cut 15″ (or if you want to be able to use the box as a stool, use a piece of 3/4″ plywood cut 16-1/2″ x 16-1/2″)
leave 1/2″ space along the long side and 1″ space along the short side
(Updated 5/25/2010: changed front and back from 1/4″ plywood to 1/2″ plywood)
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2 sides:
bottom:
lid:
Don’t waste your time with 1/4″ plywood and 1x2s. Just use 1/2″ plywood and you don’t need anything else. Use a double rabbet joint for the corners. If you want to get fancy, you can do a box joint or dovetail.
I forgot you work next to a guy with a woodworking shop. I’m going to use a staple gun and glue and be done while you are still setting up your dovetail jig.
Also, the 1x2s serve as a handle.
The 1x2s also help give the sides a nice curve.
I like curves, stick-boy!
OK, I might build one to see how flimsy it is. Then, if all else fails, I’ll finally take your advice (which you have masked into self-righteous ‘do-this’ commands), maybe.
Might use 1/2″ plywood for bottom and lid insert instead of 3/4″, which would change the front, back, and side dimensions:
2 sides:
1/4? plywood cut 16-1/2? x 8?
1×2 cut 16-1/2?
(2)1×2 cut 6-1/2?
front and back:
1/2? plywood cut 18-1/2? x 8?
bottom:
1/2? plywood cut 16-1/2? x 16-1/2?
lid:
1/4? plywood cut 18-1/2? x 17-1/2?
1/2? plywood cut 16-1/2? x 16-1/2?
another idea:
for the bottom, use 1/2″ plywood with 1×2 along the parameter, and assemble so that 1/2″ of the 1×2 is extended below the plywood sides and front/back. Now one box will serve as another’s lid. You don’t have to make as many lids and the boxes will stack perfectly straight.