Measured the camping equipment for exact dimensions and designed from the inside out.
Main objective was to make it as light and portable as possible.
- Piano Hinges (2)
- 3½” black door hinges (4)
- Recessed road case handles blk (2)
- #8 x ⅝” black oval wood screws (20)
- Chest latches (2)
- 4” ridged castor (2)
- misc. bolt h/w for castors
- ¼” - 20 x 1” Wing Screws
- 60” tapered utility handle
- 1” Rubber leg tips (4)
- Angled top plate (4)
- Hanger bolt (4)
- #10 x 1½” wood screws (24)
- #8 x 1¼” wood screws (16)
- Finishing nails
- ¾” 4’ x 4’ plywood (1)
- ½” 2’ x 4’ plywood (1)
- ⅛” 2’ x 4’ tempered Masonite board
Step 1: Boards Cut and Ready for Assembly.
¾" plywood used for top, bottom, sides and divider including the sides of the foldout doors. ½" plywood used for fold out counter tops and tops & bottoms of fold out doors.
Step 2: Assemble the Package
Drilled holes for the wood screws and dry assembled the ¾" boards, Used wood glue and screws to attach the sides, tops and inner divider. Added furniture angled top plates on the bottom of the box for leg attachment. Cut down a 60” tapered utility hard wood handle for the legs. Doubled up the thickness of the ⅛" masonite boards used for shelving due to the span to avoid sag.
Step 3: Sand, Stain and Urethane
Best time to sand, stain and urethane the box before the front and back are attached.
Step 4: Full Assembly
Attached doors with door hinges, added latches to the front doors and top foldout counter top.
Added spring loaded, recessed road case handles to both sides of the box.
Added two "kick stands on the bottom of the box. One so the box sits level and the other slightly longer so the side sits up to attach the legs. Initially the box can be tipped back on the wheels to attach the first 2 legs. Both kick stands held up in place by velcro.
Step 5: Counter Support
Instead of using the opened doors to support the folded out counter tops, I added removable shelf supports. This way the counter tops can be left open and the front doors closed.
Step 6: Lantern LP Post Support
Added a removable piece of angled aluminum held in place by 2 wing screws to support the 2-piece LP post. A hole was added to the back of the box so the LP tank hose can attach to the LP tank.
Step 7: Camp Box Layout
Camp box setup and ready for action.
Glued and nailed ½" pieces of plywood to the front and back of the top masonite shelve to store the legs, shelf brackets and 2-piece LP post.
Built side supports and using velcro to secure the lantern in place.
Supplies stored away.
Empty weight 60 lb