this how I made my box. I have a pic of it in my media. enjoy
Directions to build fairly wide 12 foot long straight box. Very sturdy.
4 2x4 12 feet long
4 2x4 ten feet long
4 2x6 eight feet long (pressure treated. these will be the feet so they need to be rot resistant)
1 1/2 inch 4x8 sheet of pressure treated plywood
1 3x6 sheet of lexan as this as possible you dont need to be able to screw it down this stuff is expensive! get it at home depot.
3 1 inch ten foot long PVC pipes
a box of tough coated screws talk to your local hardware store dealer. youll need alot of screws get extra just in case. four inch long is best but 3 inch will work just as well.
3 tubes of GE plastic and polycarbonate clear silicone caulk. get at home depot as well. 2 could be enough but if you want the pvc sideing (recommended) then go with three.
A scorer ( a small tool used to cut glass and hard plastics) get at home depot or local hardware store they will know what you are talking about.
This design will run ya just south of $200 but youâ€™ll get a hell of a box. if you short on cash plexiglass is a good substitute for Lexan as is nylon and PVC sheet which is much cheaper.
youâ€™ll need access to a table saw an electric drill with bits, and a caulking gun. you will need some friends with you to cut on the table saw its not possible to cut the plywood by yourself.
Directions: After you have all your materials get out all your equipment. Set aside a good 5 hours that is if you have a friend or two at hand.
1 start up your table saw and get your wood ready. Take your three 2x4x10 youâ€™ll cut these first.
2 mark them every two feet make sure they are exactly 24 inches long this is imperative! Cut them up youâ€™ll need 14 24inch sections for the main supports. You should use most of your 2x4x10 in this, the rest of them is scrap wood. Remember to take the guard off the table saw if you donâ€™t the wood will bind up and you could cut something of yours thatâ€™s not meant to be cut!
3 Next get your2x6x8 ready. Mark them in half about four feet. this is the least important part these will be the feet that keep the box balanced when your sliding the shit out of it.
4 now lay two of your 2x4x12 on the floor. Space them how ever wide you want you box to be mine were 17 inches apart from the inside and that seems a little big. So well say 17 inches for the directions. Align both sides youâ€™ll need a friend for this. If they are not exactly 17 inches apart your box will come out a little off. Place seven of the eight 2x6x4 pieces on them. The other is scrap. Put one on each end then space the other five out evenly along the 2x4x12s they should come out to the same distance between each foot. Make sure the feet are about even on each side so it wont rock one way.
5 once you have them all laid out evenly wip out the old drill and bit. drill three holes through each foot on each side and into the 2x4x12. now put the screws into the holes. Make sure the drill bit size is equal or slightly smaller then the size of the shaft of the screw. ( the part on the screw without threads is the shaft size)
6 now all your legs should all be attached securely. Flip the whole thing over now. Now it should resemble train tracks, with the feet on the floor and the 2x4x12s on top of them.
7 now grab your 2x4s that were cut to be two feet long. Youll need 14 of these anything extra is scrap but keep them in case you mess up. Take you 2x4 sections stand them up on the inside of the 2x4x12s one on each 2x6 leg . Space each section in the middle of the 2x6 feet presicion is not too important. Now drill through the 2x4 sections and into the 2x4x12 pieces. Finish one side then work on the other. I recommend drilling three holes in the shape of a triangle. Now put in the screws. After this step you should have something looking more like a box, a little more at least.
8 This step can be a little tricky. In this step your trying to make the platform that the pvc rail will sit on. First flip the box upside down and rest it on its vertical pieces donâ€™t worry it will hold. So the feet are now in the air. Now get some scrap plywood around Â˝ thinck and get the last 2 2x4x12â€™s. Lay this next to the vertical pieces (on the outside). You now should rest the small side of the the two new 2x4x12s onto the plywood right up against the vertical peices. This will make the 2x4x12 be Â˝ inch lower then the vertical pieces add another Â˝ for the plywood top and thatâ€™s 1 inch. Which will make the 1 inch pvc rail at the same height as the top of the box (includeing the lexan) hopefully these 2x4x12s are pretty straight otherwise this could be very hard! Put three screws through the 2x4x12 and into the vertical 2x4 pieces. Do this on both sides. It should look pretty semetrical now.with the 2x4x12s running the length of the box, and the vertical pieces on the inside of the 2x4x12s.
9 Now Take your last 2x4x10 and cut it into sections that measure exactly 17â€?. Youâ€™ll need 6 sections. (the box should still be upside down) Now put these pieces in between the 2x4x12 that run all the way down the box. But let these cross pieces rest on the ground. Make sure the 2x4x12s you will be drilling into are flat on the ground. Screw these cross pieces into the 2x4x12s. now flip the box so its right side up. It should look alot like a box now. You should get a rush of excitement knowing your almost done!
10 One of the last construction steps, cut your plywood into two sections that are 17â€? wide. As long as they both add up to 12â€™ long its fine. Put screws through the plywood and into the wooden frame. Put screws wherever you want as long as there are some in the 2x4x12s and some in the cross pieces and vertical pieces then it really doesnâ€™t matter how many you put in. congratulations you now have a box now you need to put the lexan on.
11 (Optional step) if you want to paint the top of your box nows the time. the glue will stick to any paint so donâ€™t worry. Paint it how you want and give it a day or two to dry. Remember painting requires temps of at least 50 F.
12 nows the time to score your lexan. ATTENTION DO NOT TRY TO CUT LEXAN ON A POWER SAW IT WILL CRACK! Now take something straight that is at least 6â€™ long. Make sure its straight. Measure 17 1/4â€? wide and mark. do this on both ends. now draw a straight line from marking to marking. Take a metal yard stick and use it score the lexan this will take a long time. Once you have a gouge that goes about halfway through the lexan your ready to break it. Put the sheet of lexan onto something flat ( a coffee table is good) put the part you scored on to the edge of the table. Push on the piece of lexan that is hanging loose. Start at one end and push down hard really hard. Once youâ€™ve started a rip pull the loose piece, and the lexan will rip like butter. Do this until you have 2 171/4â€? x6â€™ long pieces.
13 Take one pvc pipe and cut it twice into two two foot sections, leave the other two
14 Now break open caulk read the instructions if you donâ€™t know how to use a caulking gun. Cut the tube open and apply glue to the box not to the lexan make a semitrical pattern across the box. Do one six foot section at a time. After both sides are glued down walk on the box and make sure the glue is pressed tight. Put a lot of heavy objects on top of the box ( this is important otherwise stuff i.e. water can get underneath the lexan and it wont last for more then a season or two). Remember the air temp needs to be 40 F or higher in order for the glue to work well. Try to bring it inside because it will need 12 hours to dry. You should use one tube of glue for each section of the Lexan.
15 Now glue the pvc pipes down with the remaining tube of glue. Just put a strip of glue onto the 2x4x12s and put pvc pipes onto the glue.
16 Just let it dry for 10-14 hours and you have made a sweet box! If you want to put sides on it you can by just buying more plywood it doesnâ€™t matter though. Voila thatâ€™s how I made my sweet 12â€™ box. Donâ€™t worry ive gapped 25 feet onto this thing it can take whatever you can dish out.
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