Step 11: Mark and Drill Pilot Holes on the Side Panels

Mark Powers drills pilot holes into the side panel of a dog crate
Photo: Laura Moss
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On the exterior face of each side panel, where the corner stile trim pieces will later be attached, you'll need to drill countersinks for the assembly screws. On the side that will fasten to the face frame, draw a vertical line ¾ inch from the edge. Using a drill/driver fitted with a #6 countersink bit, drill pilot holes centered between the edge of the panel and the line, near the top, middle, and bottom of the panel. On the side that will fasten to the edge of the back panel, draw a ½-inch line from the edge, and center your pilot holes within this space.
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    Tools List

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    • miter saw
      Pneumatic brad nailer
    • pneumatic brad nailer
      Speed Square
    • speed square
      Screwdriver
    • Phillips screwdriver
      Jigsaw fitted with a plywood blade
    • jigsaw
      Miter saw
    • miter saw
      Drill/driver and various bits: 5/16-inch, 3/32-inch, and #6 countersink
    • drill
      24-inch bar clamps
    • bar clamps
      Tin snips or heavy-duty wire-cutters

    Shopping List

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    1. 14-by-14-inch inch reproduction floor heating grate

    2. Decorative cabinet grille Get enough to cover the window cutouts on the side and back panels.

    3. Dog tray for a plastic or metal crate, sized to your dog's weight.

    4. 4-by-4-foot piece of ½-inch oak veneer plywoodfor the crate's sides, back, and top.

    5. 8 feet of 1x2 oak

    6. 6 feet of 1x3 oak

    7. 2 feet of 1x4 oak

    8. 5.2-mm Lauan plywood for the crate's floor.

    9. ¾-inch square dowels to make floor supports and cleats on the back of the face frame.

    10. 3/8-inch square dowels to hold the decorative grille in place.11. 1 5/8-inch oak crown molding and ½-inch oak glass bead molding to trim the top.

    12. Pivot hinges

    13. Latch

    14. 3-inch finish-head screws for the door and face frame.

    15. 1-inch drywall screws to assemble the box and install the decorative grille.

    16. 5/8-inch brad nails to secure all trim pieces.

    17. 1 3/8-inch brad nails to secure cleats, blocking, and crown molding.

    18. Stainable wood filler

    19. Shellac and lint-free rag