I made this whelping box for a breeder friend.

It is easily foldable and without tools to be stored when not in use. It is made of 18 mm thick white melamine, has a removable door and 3 anti-crush bars.

Dimensions:

height: 45 cms
length: 100 cms
width: 70 cms

Supplies

Material:

18 mm thick white melamine
Wooden curtain bars
M8 x 40mm knurled screw
Locking latch
M8 x 15mm insert nuts

Step 1: 3D Plans With Fusion 360

I drew the plans with Fusion 360, and for the first time, I used the software's animation mode, it's really nice to see what it will look like before creating it.

I put the plan to download in PDF format, the dimensions are in millimeters.

Caisse mise bas pliable plan.pdf
Download

Step 2: Cutting Boards

I used 18mm thick melamine boards which I cut with the circular rail saw.

For long lengths, I used the table saw.

Step 3: Bottom Assembly

The bottom is 70 cms wide, as the boards are not big enough, I used 2 of 35 cms that I glued.

I assembled the 2 boards with wood glue and strips.
I mark an identical location on the 2 sides, I hollow out the location with the plate joiner, then I drive in the slats with a mallet and I assemble the 2 boards. I ensure a tightening with clamps I time for the glue to dry.

Step 4: Feet and Reinforcements

To strengthen the assembly of the bottom, I added 3 cleats which are screwed below. They also serve as feet for the crate.

Step 5: Small Sides

I continue with the cutting of the sides.

The front will receive a small door, I cut it with a jigsaw.

Step 6: Hinges

I used piano hinges. I cut them with a hacksaw and screw them in with small 16mm screws.

Step 7: Large Sides

To be able to fold the long sides, the hinges must be higher than for the short sides.

There is therefore a fixed part which receives the hinge for the mobile part.

Step 8: Melamine Edging Tape

Everywhere there was a cut, I stick a edging tape.

This edging tape is hot-glued with an iron. I add baking paper between the tape and the iron to avoid damaging it.

Then I cut the excess with a cutter

Step 9: Fixings

To keep the box open without the need for tools, I used locks toggle catch.

There are 4, screwed into the melamine.

Step 10: Finishing Profile

I used aluminum finishing profiles that I cut and glued over the entire upper part of the crate.

Step 11: Anti-crush Bars

For the anti-crush bars I used wooden curtain rods. I added screw-in inserts to the ends, and they are attached to the bass box with knurled screws.

Step 12: Gallows

With melamine scraps, I created a gallows that will be used to attach a heat lamp.

It is also secured with knurled screws.

Step 13: Assembly of the Crate

The assembly is easy, we start by raising the 2 small sides, then the 2 large ones, we lock the latches, we install the anti-crush bars, and finally the gallows.