First things first: please be safe and careful when using any tools. I nearly put a misfired crown staple into my thumb on this project because I was rushing - believe me, it slows the whole project down when you're trying to pry chunks of metal out of your digits, so take your time and be safe!
The tools I used:
- Table saw
- Mitre saw
- Panel saw
- Crown stapler
- Drill press
- 3/4" plywood
- 1"x4" pine
- wood glue
- heat register sheet metal (this has a proper name but I'm not sure what that is)
- double-sided carpet tape
- black duct tape
Step 1: Cut the Wood!
The framework of the box was really simple glue and crown stapling the 1x4s together; next I added four strips of 3/4" plywood. I tried to make these strips flush to the top so that later I can lay the register metal across it.
Step 2: Add an Angled Base
With some help from a mallet I convinced the plywood to fit into the 1x4 frame; I added some sealant to make sure the vacuum suction will only come through the grate on top.
I was trying to figure out how to make the register metal stay flat on top of the plywood strips and happened upon an old roll of carpet tape - perfect!!
Step 3: Put on the Top
I wrapped the box in black duct tape so Tina wouldn't cut herself on the metal edges. And that's it - you're done!!!
Tina found while using it that she could get better suction by masking off some areas with paper towel. She said it might work better with a hood around it so that any dust not directly caught by the suction would fall back onto the grate.