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Measure the width of four side planks lying side by side; then add 6" to figure the length of your A side battens (2 1/2" for the channel, plus 1/4" between planks, plus 1 1/2" rabbets at each end). Cut four 2 x 4s to the A length and four that are 2" longer for the B side battens; then rip them all into 2 x 2s (actual size 1 1/2" x 1 1/2") so you end up with eight of each.

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The next step is to cut the 1 1/2" wide by 3/4" deep rabbets on the ends of the battens. I used dado blades on my radial arm saw and damped a stop block to the fence to make them all the same. Now mark the centers of each rabbet for the holes that fit over the pins.

Pull out four battens of each length to use as the top and bottom frame members. Drill 5/8" holes in the ends for the pins. Drill 3/4" holes in the other eight battens. Cut 4" long pins from a broomstick or a 5/8" dowel and round over the ends.

Putting It Together

To assemble the frames, use Elmer's outdoor wood glue in the rabbets of two A battens and two B battens and all over the bottom half of the pins. Drive the pins in place and check the assembly for square by measuring corner to corner. If the measurements between diagonals are the same, it's square. I further reinforced this joint by driving a 1 3/4" screw into the pin at an angle that captures all three pieces.

Now assemble the A sides by laying two of the shorter battens on the floor with their rabbets facing the same direction. Lay one side board across the end of the battens, aligning it with the shoulder of the rabbet. Use a framing square to help you position the battens 1 1/2" from the ends of the board and also perpendicular to it.

Attach the board to the battens with 2" deck screws. Lay another board at the opposite end of the battens and repeat this procedure. Now position the two middle planks and screw them to the battens.

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