We just rebuilt our crate due to weight issues and found Team 246's plans very useful.
Follow this link for the plans:
http://www.burobotics.org/build_a_crate.pdf
We only changed a couple of things, we used 3/4 sheating for the bottom and top for more rigidity, used a few more bolts than suggested, used regular nuts on three sides instead of wing nuts, and just used wing nuts on one side for access. We also used 2x4's which we ripped down in half instead of true 2x2's. We added a third 2x2 brace in the middle of both 46 inch 3/8" thick sides to secure it up a bit. We haven't weighed it yet, but one student and I could lift and curl the box fairly easily so my guess is below 200 lbs fully assembled probably around 150 lbs. Our old crate was most likely in excess of 280 pounds. Thanks for posting these plans 246! We picked up materials and built the box in less than a day and now we need a bit of paint to finish it up.
Pat Daley
Mentor
Team 1370