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Step 3The Plywood Slate Backer
In this step you'll create the plywood backer that the slate tiles rest on.
Cut a piece of plywood that fits inside the frame. Your frame may not be perfectly square, so take careful measurements and make careful cuts. Barring the use of a table saw, the easiest and most effective way to accurately cut plywood is with a circular saw. A jigsaw can be used, but it's hard to get straight cuts with a jigsaw.
Big box home stores might be able to cut the plywood to your specifications for a nominal fee. This would probably be the way to go if you lack the tools or desire to do it yourself.
Once you're finished cutting the base, there's the optional (but recommended) step of cutting notches so that the wooden backer rests flush on the file base's metal tabs, and not on the welds of the metal tabs. The picture below illustrates this step.
Mark the location of the welds and cut away a small amount of the wooden backer to accomodate them. You can use a chisel, file, or dremel for this.
You can choose to seal or paint the wooden backer if you like. It's not necessary, however.
Cut a piece of plywood that fits inside the frame. Your frame may not be perfectly square, so take careful measurements and make careful cuts. Barring the use of a table saw, the easiest and most effective way to accurately cut plywood is with a circular saw. A jigsaw can be used, but it's hard to get straight cuts with a jigsaw.
Big box home stores might be able to cut the plywood to your specifications for a nominal fee. This would probably be the way to go if you lack the tools or desire to do it yourself.
Once you're finished cutting the base, there's the optional (but recommended) step of cutting notches so that the wooden backer rests flush on the file base's metal tabs, and not on the welds of the metal tabs. The picture below illustrates this step.
Mark the location of the welds and cut away a small amount of the wooden backer to accomodate them. You can use a chisel, file, or dremel for this.
You can choose to seal or paint the wooden backer if you like. It's not necessary, however.
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