This is going to be an "in flight" project I think lol...
But we want a kennel for the house so I have a sheet of plywood and two 10' boards of Poplar. So quickly put together something in Fusion and had to screw around with the layouts and make some concessions, but I think it will work. Going to start tomorrow and see what happens but may need to make adjustments mid stream.
The kennel section is roughly 45" x 27" x 31". The dimensions are kind of odd b/c I was playing with some constraints of where we want to put it plus it being large enough for the pup. That part doesn't really mess with dimensions too much, more like where I put my divider and then the shelf width. The case is plywood with an inner plywood frame on the kennel part. Then I'll frame the outside in the poplar.
The center divider is janky because I can't get a bottom and two solid panels out of one sheet. But if I split that panel up in to two 15" and join it with the shelf, I can get it all out of one 8x4 sheet and have enough left on the ends to frame out the inside of the kennel.
Found a local Pipe and Supply store and just showed one of the guys my idea and he took me around their warehouse / work floor looking at all their options for 1/2" OD, aluminum, stainless, tube, pipe. They're cutting me 25 pieces of 30" aluminum that should be ready to pick up tomorrow. That'll make up the crate part. Thinking 3.5" spacing on center which will give me 3" between bars. Need to look at that in person though before drilling the holes.
Still need to figure out what to do for the top. Have some Red Oak. Really wanted to do Sapele but it is a little more than I wanted to do, may still do that. Also sort of depends on what we want to paint this thing. No feet or anything, she wants it sitting on the carpet.