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Thread: A Great Crate....

  1. #1
    Join Date
    Oct 2006
    Tokyo Japan

    A Great Crate....

    I guess this counts as flatwork

    Recently a buddy of mine who works at the British Embassy here in Tokyo asked for my assistance in an interesting project.

    There is this British gal named Sarah Outen who is attempting to go around the world on human power only.

    She has two boats, a sea kayak named Nelson, and an ocean going rowboat named Gulliver, and a sturdy bicycle named Hercules. She has just arrived in Tokyo after cycling down from northern Japan. Her sea kayak, Nelson, will now be shipped ahead, back to the UK, I think, where she will use it next year some time. Now she will rest in Japan over the winter and then next spring head out to cross the Pacific ocean in her row boat, it will take her a very long time to row to North America.

    When Nelson was shipped across europe and Russia for the last time she used it, the crate was not very good, and Nelson was partially crushed.
    This time they wanted a good solid crate so Nelson would arrived in one piece. Mike is a cycling friend of mine, but he knew I like to play with wood, so he asked for my help to build a crate for Nelson.

    Let me tell you about Nelson, he is 17' 1' long, about 19" tall and 21" wide, not the usual size of something that is crated up and shipped. When Mike contacted a few shipping companies about crating Nelson up for travel, they mostly said "No thanks", the one that said they would consider it, wanted about $1200 for just agreeing to the job, and most likely more than that by the end of the job. Wow, I'm in the wrong business!! As Sarah is self funded, I jumped at the chance to help out.

    One more thing, the whole crate had to be made from OSB because of shipping regulations...

    I decided that we needed to make a torsion box, this would provide a very solid base for the whole crate, and while I know it certainly might be considered overkill, that is just the way I roll

    Nelson is suspended inside the crate by two straps that work kind of like a cradle under the kayak, and then two straps are attached to the t-handle lift ropes on both ends to hold him down. This way no even if the crate were flipped upside down, the kayak would still be held in place. The crate was a little snug around the middle, so we put some carpet between the sides of Nelson and the sides of the crate.

    All told about 15 sheets (3'x6' sheets) of 9mm thick OSB, a bunch of staples and glue and we had a crate, a great crate!! The whole deal, kayak, equipment, and crate weigh about 180 Kg, or just a touch under 400lbs.
    Below you can see a quick slide show that Mike made, I don't have the pictures just yet, so the slide show will have to do.

    >> Video Link <<

    Took us about 8 hours total, but that includes a very tasty lunch at Tony Romas just around the corner.

    Total cost, just over $200, I think Nelson will arrive at his next destination safe and secure.

    The pessimist complains about the wind; the optimist expects it to change; the realist adjusts the sails.
    William Arthur Ward

  2. #2
    Join Date
    Feb 2007
    North West Indiana
    Can't view the video here at school, but sounds like a formidable crate and what is needed. Good job on you! (AGAIN!!!)
    God and family, the rest is icing on the cake.

    I'm so far behind, I think I'm in first place.

    Premier Bovine Scatologist


  3. #3
    Join Date
    May 2007
    Kansas City, Missouri
    Looks really sturdy Stu, nice work!

    To a small child, the perfect granddad is unafraid of big dogs and fierce storms but absolutely terrified of the word “boo.” – Robert Brault

  4. #4
    Join Date
    Dec 2007
    Los Angeles, CA
    That should work. Nice video pictorial. I liked the part where you are posing sitting on the crate.
    Chinese Proverb: Man who eats many prunes gets good run for the money.

  5. #5
    Join Date
    Aug 2007
    Reno NV
    Like Larry says, "When in doubt, build it stout". That certainly fits the bill!
    Programmer - An organism that turns coffee into software.
    If all your friends are exactly like you, What an un-interesting life it must be.
    "A door is what a dog is perpetually on the wrong side of" Ogden Nash

  6. #6
    Join Date
    Nov 2006
    London, Ontario
    Where there size constraints on the crate? I'm just curious as to why you didn't make it a bit wider, so there was more space between the crate and the sides of the kayak.
    Will it be shipped by air, or by ship (container ship?)

    Entirely OSB, weird requirement....

    good job, Stu!
    There's usually more than one way to do it... ........

  7. #7
    Join Date
    Oct 2006
    Tokyo Japan
    Thanks guys!
    There were not constraints, but they add up the three dimensions and charge you for the shipping, so the smaller it was the cheaper it was, and like I said, Sarah is totally self funded, as in her own money, or money she raises by speaking dates or donations etc, so saving her money was high on the priority list.
    Whatever is used to build the crate has to meet the ISPM15 standard and have that stamp on it, or DHL would not take the crate for shipping to the EU, funny think the OSB we got was actually made in Bulgaria, so that means it was shipped to Japan from the EU.....
    The pessimist complains about the wind; the optimist expects it to change; the realist adjusts the sails.
    William Arthur Ward

  8. #8
    Join Date
    Mar 2008
    Well I guess it wont get away
    It could be worse You could be on fire.
    Stupid hurts.

  9. #9
    Join Date
    Oct 2006
    ABQ NM
    Dang, put wheels on that crate and she could drive it around the world. Nice job, Stu.
    When the going gets weird, the weird turn pro. - Hunter S. Thompson
    When the weird get going, they start their own forum. - Vaughn McMillan

  10. #10
    Join Date
    May 2009
    Lafayette, Indiana
    Well done Stu. I'm sure this will really help her on her journey.
    It's not what you achieve in life...It's what you overcome!

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