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Construction

General assembly notes:

a. With 1/16 " drill bit, drill pilot holes through plywood to start all nail and screw holes. b. Apply a bead of construction cement in all wood joints.

Steps:

1. Cut ply into:

One 5' 4" x 2' 6" wide bottom panel; Two 5' 4" x 6" wide side panels; Two 2', 6" x 6" wide end panels; Eight 6" triangles for corner gussets.

2. Cut framing from 2" x 3" studs, the sides first.

Lay the bottom panel on the ground and cut two lengths of 2" x 3" to be as long as it is. These will be the sides of the frame.

3. Fasten side-frame boards to the plywood bottom panel.

With smooth, finished face of the bottom ply facing up, set a 2" x 3" frame side board under each long edge, the 2" x 3"s "on edge"—with wider 3" surface facing out. Be sure outer edges of frame boards are even with edges of the bottom sheet. Fasten with screws 6" from end and placed every 6' ; screws will be through ply and down into the 2" x 3"s.

4. Cut frame ends and cross braces to fit bottom panel. Turn bottom panel over. Measure and cut 2" x 3"s to fit between ends of the frame boards just screwed on. Measure and cut 5 other lengths of 2 x 3 to form a ladder shape of cross braces between frame sides.

5. Tack fasten ends and braces. Arrange frame ends and cross braces in a ladder shape on underside of bottom panel. Cement and tack in place with long, easily removed nails through 2" x 3"s and into ply.

6. Reinforce underside of corners. Cut four triangular braces from scrap ply and place one at each corner. Use cement and short finish nails to fasten.

7. Carefully turn ply over again. Set screws through bottom panel and down to the frame members, screws about every 6". Now the bottom is framed.

8. Next, "box in" framed bottom with plywood side and end panels. Lay out the 5' 4" plywood side panels along the framed bottom, lower edge of side panels even with bottom edge of frame.

9. Lay out the plywood end panels. Arrange and (as needed) trim ends of sides and ends so all corners meet in a butt joint (end of one meets side edge of the other). Fasten sides and ends to frame with screws 6" apart, 1/2" up from lower edge. Remove tack nails from underside.

10. Cut and install corner cleats to strengthen up side of corners. Trim about a foot of scrap 2" x 3" to be a 1/2" square. Measuring in the box, cut four approx. 3" cleats—one to fit into each corner, upper end even with the rim. Drill stag gered holes 3" in from corners and fasten cleats with glue and 1" screws through ply into cleats.

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