This project uses only one sheet of plywood. It makes a four level step that is 32 3/4 inch tall. I use mine for my kids (2 and 5 yr old) to get on to the trampoline, you can use yours for whatever. Hope you enjoy!
Step 1: Tools and Materials
Tools and Materials needed:
1 Sheet of 3/4 inch Exterier Plywood
A Large Square (Makes 90 degree)
Nails and Hammer
or Nail Gun and 2 inch long nails
Wood Screws (I used 1 1/4 inch Coarse Thread)
Pilot Hole tool (Makes room for the head of the screw and not crack the wood)
Sand Paper and Sanding Block
or Jitterbug or Orbital Sander (electric or pneumatic)
Hand Saw (I do not recomend takes way too long)
or Circular Saw and Jig Saw
Step 2: Planning
I reccomend you take some graph paper and a pencil and sketch out how to fit all of these parts onto one sheet of plywood. Use my design. For my graph paper I made each square represent 2 inches, that way a 4 x 8 ft sheet of plywwod is only 24 squares wide and 48 squares long. Here is a list of parts and sizes for each that you will need:
Piece Size In Planning Photo #
Mid - 32 x 32 (stairs are each 8 inches tall in a zig zag) - Photo 2
Right -(Steps 1 & 3) 32 x 24 x 8 x 16 (looks like a L with a large back) - Photo 2
Left -(steps 2 & 4) 24 x 32 x 16 x 8 (looks like a L with a tall bottom) - Photo 2
Bottom of R - 9 x 31 1/4 - Photo 3
Bottom of L - 9 x 23 1/4 - Photo 3
Back - 20wide x 32tall on L x 24tall on R x 10 1/4across at top - Photo 3
Front of 1 - 9 x 7 1/4 (I used this at the back of 1 for support) - Photo 4
Front of 2 - 9 x 16 (I used this at the back of 2 for support) - Photo 4
Front of 3 - 9 x 15 1/4 - Photo 4
Front of 4 - 9 x 18 (or longer than 18 if you have extra room) - Photo 4
Top of 1 - 13wide front x 17long x 11wide at back - Photo 5
Top of 2 - 13wide front x 17 long x 11 wide at the back - Photo 5
Top of 3 - Exactly the same as Top of 1 - Photo 5
Top of 4 - 12 x 12 - Photo 5
I realize you can not read my pencil marks on this pic, but you can see where to put each piece. You might can read the marks on the cut out versions better. For a better view of the pieces check out the next step: Cutting and look at Pic 1 and 2.
Step 3: Cutting
Take a pencil and mark up you plywood (all the pieces) on your board. Make sure they all fit (don't forget that the blade of the saw takes out 1/8 of an inch, so leave room! Use the graph paper. Then cut each piece and mark them on an edge or inside that won't show what piece they are (ie: Top of 1 or Bottom of R). There is a little bit of extra room on the sheet of plywood but try really hard not to make a mistake, else you defeat the purpose of making this out of one board. You can see from the the grain of the board in pic 1 that it is cut from one 4 x 8 piece of plywood. In pic 2 you can see them spaced out some.
I cut the Top of 1,2,3 and 4 out square and I tell you in the next step how to round off the edges. Leave plenty of room for that!
Step 4: Mock up
After all the pieces are cut, I would start by using clamps and putting the pieces together and see how they fit. Do not glue or nail or screw, just place them together with clamps to make sure everything fits (pic 1). Before this shot, I took the Top of 1 2 3 and 4 and used an old coffee can(6 inch diameter) or what ever gives you a nice curve and cut the edges off the corners of all the Tops (or steps). On Tops 1 and 3 (both of these are exactly the same) the front two edges are rounded off and the back right edge but not the back left corner. The back left edge or corner has 8 straight inches till the start of the curve to the outer side. Then on Top 2, opposite from 1 and 3, take and round off the front two corners and the back left. Then on the back right edge come 8 inches up toward the front and make you curve ( pic 1).
Step 5: Building
Once you got everything how you like start with the Mid and a side, I started with the left. Get the Mid and the Left and the Bottom of L and the wood glue and screw them together (pic 2). I used corner clamps to make this easier (I forgot to put these in the original pic, sorry) The two screws you see here will be covered up by Bottom of R. Pic 2 shows the Front of 2 where it is suppost to go, if you want these steps enclosed. It was at this point I decided not to cut holes in the side of this project for shoes and leave the Front of 1 and 2 off, but then I figured I needed the support, so I but them at the back of the steps (pic 2 and 3).
The next piece I put together was the Front of 2 and 4. Then I put on the Bottom of R and the Right side. Then the Front of 1 and 4 (yes if you do it my way (leaving a place to put shoes under Steps 1 and 2) the Fronts overlap). see pic 2 and 3. I would use glue and screws where ever possible and then nail it together with a nail gun just for more support. I left the Tops last and the back for very last.
Step 6: Paint
I choose to seal the steps with Thompson's because it will sit outside and needs to last at least till the kids are big enough to climb into the trampoline themselves. You could paint it up any color, or one idea I had was to take it to a shop and have it sprayed with truck bed liner! That would make it last, have it Rhino Linered! You could add a stain to the seal if you wanted.
Step 7: Enjoy!
Enjoy! Here are a few shots of the finished project.