I should call this "Best Laid Plans" because of the way things worked out. I had planned to go get the crating board I need, crate the cabinet over the weekend and ship it Monday morning. Unfortunately it rained all day Friday, Saturday and Sunday; no opportunity at all to get the supplies I needed -- which would have been ruined by an hour long ride in an open bed pickup, at interstate speeds, in a deluge.
So, Lori, I'm terribly sorry for the delay.
Once the materials were on hand, here's how we crate up a piece of furniture.
We begin by shrink wrapping it to help keep the drawers pulled in and not jiggle up and down so much.
Then we take 4' x 8' sheets of Styrofoam and cut it into 3" wide strips.
These strips are cut to length and applied to the cabinet. Two or three layers may be needed to build out where we have protrusions like knobs and overhangs. We use duct tape to fasten the strips to one another, but are careful not to let the adhesive touch the cabinet. A top plate of foam is cut to size and fastened in over the entire top of the cabinet.
We repeat the process around the base and affix some extra strips on the front, again to help prevent the drawers from moving around during shipment.
We do not wrap the entire cabinet in two or three layers of foam because the heavy duty, triple wall corrugated board we use for panels offers enough puncture resistance that the foam would be redundant. And this foam is getting expensive, so to hold your crating fees down we use just what we need.
Next we cut and apply the corrugated side panels. At a half inch thick, this stuff is very stable and stiff. We use masking tape to hold the panels together for the moment.
Once the panels are all in place we rip 1/6 pine lumber into strips to use in bordering the corrugated panels. These probably aren't necessary in a crate this small as the corrugated panels have so much rigidity and crush resistance (when corrugations are run vertically) that they alone *may* prevent the crate from being crushed if another box is stacked on top of it in the truck trailer. But to get the best rate from our truck line, a crate is defined as being wood reinforced. So we apply the wood: nailed together and glued to the corrugated panels.
To finish off, we build a pallet style base that allows the crate to be easily moved and lifted with a fork-lift or pallet jack. Then we run the shipment through Old Dominion's web site, generate the bill of lading and shipping label, and it goes out on the dock to await a ride to
This process took 5 1/2 man hours to complete, not including the run to