Gray-B-Gon wind-powered evapotron for graywater disposal

Step 7 Cut wood and varnish it

Summary:

• Cut 1/2" plywood into three trapezoids (corners trimmed) and four rectangles.
• Cut 2x4's for tray frame.
• Cut 1/4" plywood for tray and staples.
• Cut 2x2's for masts.
• Sand edges and varnish all wood pieces.

Materials:

• 1/2" exterior-grade plywood, 11" x 25" or larger.
• 1/4" exterior-grade plywood, 32" x 48".
• two 8-ft 2x4's, or enough material for two 45" lengths and two 29" lengths. If you can, avoid pieces with warps or twists.
• enough 2x2 material for a 5-ft and a 1-ft length.

Cut three trapezoids from 1/2" plywood, and remove 3/8" from the sharp corners. Trapezoids will become one propeller arm and gussets for the two masts. Cut four rectangles, 1-1/2" by 6" or so, for feet under the tray's corners.

Cut 1/4" plywood as shown, to produce a 32" x 45" tray floor and eight 1-1/2" squares (which I will call "plywood staples").

Trim 2x4 mill ends, then cut into two 45" lengths and two 29" lengths.  These are the only wood cuts that must be exactly square.  Use a table saw or chop saw for this.

Cut the 2x2 into two lengths:
60", which will become the "power mast,"
12", which will become the "idler mast."

Sand corners and edges to round them.  Stack the 8 staples and drill a 1/8" hole through the centers.

Spread a drop cloth and varnish all pieces, especially end grain and plywood edges. (Yes, this really is a time-saver, compared to replacing checked, delaminating, and splintery parts a year from now.)