Step 1: Cut Panels
- Floor: 1/2" plywood, 40" x 48": standard GMA pallet size.
- Ceiling: 3/8" plywood, 40" x 48"
- Side Walls: 3/8" plywood, 40" x 82"
- Back Wall: 3/8" plywood, 44.25" x 82"
- Door: 3/8" plywood, 43.75" x 80"
The panels were too big to cut indoors, but it was thirty below outdoors. I need a new pair of gloves.
Step 2: Move Indoors
Our house came with a free-standing workshop containing a potter's wheel, a kiln and (most importantly) a wood stove.
Step 3: Build Pallet
The floor panel is the top of the pallet. The rails are 2x4's. The cross-members are 1x4's. Everything is held together with deck screws.
Step 4: Cut Stringers
The stringers are 2x2's except for the door stringers, which are 2x4's. I cut the vertical stringers full-length, and cut the horizontal stringers to fit between the vertical stringers.
Step 5: Drill Bolt Holes in Stringers
Drill 5/16" holes to accommodate 1/4" carriage bolts.
Step 6: Attach Stringers to Panels
The stringers are attached to the panels with deck screws.
Step 7: Assemble Crate
Get a helper to help you balance everything, then bolt everything together using carriage bolts, washers and wing nuts.
Step 8: Install Door
Shim the door into position, and install the hinges. The hinges are screwed in on the door side and bolted in on the frame side.
Step 9: Install Doorknob
Use the template and instructions that came with the knob. You'll need a hole saw and a spade bit.
Step 10: Install Flooring
I used a carton of inexpensive no-nail, no-glue, snap-together laminate flooring. I cut the pieces to length with a chop saw. You want to monkey with the lengths to avoid having them look like they're laid in a grid.
When you get close to the door, stop and install the bracket for your transition board, then rip the last piece of flooring to width so it runs up to the bracket, then snap the transition board onto the bracket.
Step 11: Prepare Ceiling
Before we paint the ceiling, we want to install T-nuts for the Vaporproof light and cut the hole for the ceiling light box.
Step 12: Paint Ceiling
I rolled the celing with water-based latex primer, then taped the edges, then rolled it again with a mix of primer and Sand-Tex.
Step 13: Prime Walls
Step 14: Paint Walls
Step 15: Dither Walls
I mixed some green paint and some primer, then dabbed the walls with a paint-soaked rag until I had to go ice my arm.
Step 16: Install Molding
I mitered the molding with the chop saw (not your best option for a pro-quality job) and glued it to the walls with construction cement.
Step 17: Build Prompt Box
Size the prompt box to contain your flatscreen monitor, a sheet of one-way glass held at forty-five degrees to the monitor and a camera staring through the clear side of the glass. You will eventually want the box to be light-tight.
I built a little adjustable wooden rig with a 1/4" bolt as a camera mount.
A wireless lavalier mic will help keep spaghetti to a minimum.
Step 18: Attach Prompt Box
The prompt box bolts onto a U-shaped frame of 2x2's that are deck-screwed onto the left-hand wall. A window is cut in the wall, inside this frame. I cut the window using plunge-cuts, which is dangerous and not recommended!
Step 19: Prime Prompt Box
Prime Prompt Box
Step 20: Paint Prompt Box
Flat black inside, high-gloss Carnival Red outside.
Step 21: Hang Picture Frame
I bought a nice-looking picture frame to frame the window. I attached it using construction cement.
Step 22: Install Ceiling Light
Install Ceiling Light
Step 23: Install Vaporproof Light
Install Vaporproof Light
Step 24: Integration Testing
Step 25: Travel Through Time
Otherwise what's the point?