Step 3: Outer Box
- Start by marking the 1X8 by 8ft board at the following intervals: 23”, 46”, 66” and 86”. Using a circular saw, cut the board at these marks.
- Using the 2 20” long pieces, make 2 pilot holes on each end. The pilot holes should be 1/2” from the edge.
- Find a flat surface, and stand all 4 boards up to form a box. The 23” long boards should go inside the 20” boards.
- Measure the halfway point on both 23” board, near the bottom edge of the box. Drill a pilot hole on each halfway point, 1/2” from the bottom edge. Cut a 18” piece of 1X1, and insert it between the 23” board at the halfway point. Make sure this board is flush with the bottom of the box and screw it in place using 1 1/2” wood screws.
- From the remaining scrap sheet metal from Step 2, cut a piece 25” by 20”. Using 3/4” wood screws, attach this to the bottom of the outer box. Use the middle support board as additional reinforcement for the bottom. Place a screw every 4” or so around the perimeter of the box.
- Using the 2 20” long pieces, make 2 pilot holes on each end. The pilot holes should be 1/2” from the edge.
- Find a flat surface, and stand all 4 boards up to form a box. The 23” long boards should go inside the 20” boards.
- Measure the halfway point on both 23” board, near the bottom edge of the box. Drill a pilot hole on each halfway point, 1/2” from the bottom edge. Cut a 18” piece of 1X1, and insert it between the 23” board at the halfway point. Make sure this board is flush with the bottom of the box and screw it in place using 1 1/2” wood screws.
- From the remaining scrap sheet metal from Step 2, cut a piece 25” by 20”. Using 3/4” wood screws, attach this to the bottom of the outer box. Use the middle support board as additional reinforcement for the bottom. Place a screw every 4” or so around the perimeter of the box.
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