There are a couple of things to note.  All
three versions of the my crate would follow the same instructions.
I just tweaked the print out for each one.  Each of them is a
available on the Downloads page.
Yes, I know the side image of the German crate was altered
slightly. And no, I won’t make one that is 100% accurate.
Third, the Ark won’t fit in this crate as built.  I have some
plans to make one that will, but you will need to wait for it.
At the time I build this one, I didn’t have the “modern” Ark, so
didn’t see the dimensions I needed.

Tools you will need:

• Pen or Pencil.
• Small Ruler.
• Large Ruler or Straight Edge.
• Cutting Mat (Scrap Cardboard would work, but
  I prefer a cutting mat.)
• Glue Gun (Not Shown.  I have a low-temp
  version)
• Double Sided Adhesive tape. (I use Duck
  Brand.  It’s found in the office supply section of
  Wal-Mart.)

Materials:

• Black Foam Core Board. I really like
  the black foam core with the black middle portion. It tends to
  not show seams as much as the white. You can use the white, but
  I’d color any of the seams that look like they’d show with a
  black magic marker. You could use cardboard or matte board as
  well, but you will need to adjust the piece dimensions to
  compensate.
• Paper. I normally use a heavy
  gloss paper for these projects, but I didn’t in this case. I
  actually used plain old laser printer paper. It has a bit more
  texture than the stuff I normally use, and look good with the
  wood print.

Step 1.

Cut out all the pieces you need.

• Top (3″ x 1.625″)
• Side 1 (3″ x 1 13/16″)
• Side 2 (3″ x 1 13/16″)
• End 1 (1.5″ x 1 13/16″)
• End 2 (1.5″ x 1 13/16″)

Download and print out the graphic for the out side of the
crate.  You can see in the picture I left tabs a little
longer than the graphic.  Also, I tend to cut the tabs at a
bit of an angle on the end.  This can be seen later in the
pictures.  (Download Graphics
here.)

Step 2.

Glue one of the long sides to the top.  The side should be
flush with the two ends.

Step 3.

Next comes the first end piece.  It will go in between the
side pieces when finished.

Step 4.

Next, the other end piece.  Pretty easy so far huh?

Step 5.

Glue on the other side and you have a box.  At this point,
I normally trim any excess glue or trim an loose foam..

Step 6.

The next three steps go quickly.  Before
proceeding, I test fold the graphic.  It’s a lot easier to
fold without the adhesive on it.  Plus, it’s easier to fix
problems at this point.  I put adhesive on the “decal”
everywhere it was needed.  The back of each of the tabs and
around the edges of all five sides.  I also put a little
extra in the center of the top.  When that’s done, but the
box upside down in the center using the folds as guides.

Step 7.

Next fold the ends up and glue the tabs down to the sides as
shown.  You can see here a better view of how I cut the tabs.

Step 8.

Fold the sides down and press them in place.  Volia!
You’ve got an Ark crate.  Now, depending on how far you want
to go, you could stop here.  For more of the finishing
touches keep reading.

Step 9.

To make the handles on the ends, I bought some heavy upholstery
thread.  I have a pretty decent size needle that I threaded.
I pushed the need through the hole on the graphic, making sure to
leave one end of the thread hanging out.   I then
threaded the needle again repeated for the other hole.  If
you have a thimble, this is a good step to use it on.

Step 10.

Once I got the loop the length I wanted, I secured it inside
with a length of tape.  Then repeat the process on the other
end.

Step 11.

To make the holders for the carrying poles, I used staples out
of my staple gun.  Office staples might work, but the
thickness was better on these.  (It was Mrs. Nerd’s
suggestion.)  To start, I used a staple for a template and
pressed it into the crated just enough to make a mark.  Us
one of the boards as a marker so you can match the other end
later.

Step 12.

Once marked, I used my  hobby knife to cut a little notch.
This is way easier than trying to push a staple in, trust me.
I didn’t secure the staples with glue, you could if you wanted.
Repeat this step until all four corners are complete.

Finish:

Add two 6 inch pieces of small square balsa wood.  Press
the staples up against wood pieces, and your crate is complete!

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