This was a project I embarked on because I thought it would be quick and easy. I wanted something I thought I could finish in a single trip to TechShop. With a little more planning I could have done this but it would have been a long day so it ended up taking me 2 days or roughly 8 hours. I ran into a few problems with my design and available tools but it wasn't a big deal.
1 sheet of 3/4 in plywood (4'X8') I chose birch
Screws (I had 2.5 in outdoor screws lying around that I used)
Drill - bits and countersink
Jig Saw/Scroll Saw
Optional - Clamps
I searched for a few designs out there and found a few good starts. Ultimately, I wanted something I liked.
I found a site has a step by step for their plyo box but there were a few things I didn't like. I used their original layout found in the PDF and modified it for my use based on other designs I saw.
The Rogue Box pictured in this step is what I modified the above plans to match. I like the interlocking pieces and am familiar with them from my own crossfit work outs, I was also curious why they cost $150 to buy!
To modify the design, each piece extends to the full extent of the box dimensions.
So: Two 20" X 30" pieces, Two 20" X 24" pieces, Two 24" X 30" pieces
I chose to make the pockets for each piece a different size. For a 30" long side, the pocket was 10". For a 24" side the grove was 8". For the 20" side, I decided a 6" pocket with two 7" sides was easiest to track, measure and cut.
The sketch is my poor mock up to track the pieces and how this was all laid out.