Introduction: Plyo Box
We've been super into fitness the past year or so, so this was such a fitting client project for us! Yup, client project! Client builds is how we got started with our woodworking business back in 2016, so this was nice getting to make something for someone else's space for a change. This project is how we built a plyo box (plyometric box) for a local personal trainer. We added in his logo for a nice customization touch!
If you are interested in how to start your own woodworking business, we have some blog posts and videos sharing some advice and exactly how we got started. https://www.woodbrew.tv/5-tips-on-how-to-start-a-...
FREE Set of build plans for this project: https://www.woodbrew.tv/product/3-in-1-plyo-box-plans-free-plans/
Step 1: Cut Material to Length
Starting off with our sheet of plywood on top of our work tables with a 4x8 sheet of foam underneath, we cut our plywood down to a more manageable size. These cuts are just over the dimensions we need so we can make them straighter on the table saw. You can use a circular saw for all the cuts, but since we have a table saw, we figured we would use it. We will need 6 sides. Top and bottom are 30" x 20", front and back are 30" x 24", and the sides are 24" x 20".
Step 2: Making Tabs for Joinery
Each side is going to be put together by tabs, this kind of reminds me of Tetris, lol. First, we went around all the edges and marked in 3/4". Then alternating each side from having a tab to not having a tab. We used the table saw to cut out each tab and gap and then used the jigsaw to complete the cut. Again, can totally do this with a circular saw and not a table saw, but you'll still need a jigsaw or flush trim saw to complete the cut, since a saw blade is round. You can watch the video above to get a more visual explanation for both using a table saw and a circular saw.
Step 3: Customizing the Box With the X-Carve
We want to customize this box with our clients logo, so we brought the front piece over to the X-Carve and carved in the logo and the heights of each side. That way when you are using the plyo box, you can know what height you are using.
We used the down-cut spiral bit from Bits&Bits on the X-Carve. You can use the code "WOODBREW15" to get 15% off your order! Seriously, these are the best bits we've used.
Step 4: Cutting Out Handles
This is going to be a pretty big box and nothing is more awkward than carrying something like this. We added in some handles in the side pieces to make it easier to carry. We used a forstner bit to make the rounded corners and then a jigsaw to cut out the rest.
Step 5: Epoxy
One of our client's colors is purple, so we thought we would mix up some purple epoxy to pour into the logo and numbers. If you don't have an X-Carve to do this, you could totally paint on the logo and numbers! We used Total Boat's High-Performance Epoxy that is a 2:1 ration. This stuff is great when you add on the pumps because you don't have to measure anything out, it's just one pump of each. For the dye, we used their blue and red and the purple came out just how we wanted. Highly recommend using a pipet or syringe for doing detail epoxy work like this, we didn't have either so we poured the epoxy into a plastic bag and cut the tiniest bit off the corner so we could dribble it into the carves. We let this cure overnight.
You can use the code "WOODBREW1" for 15% off your Total Boat purchase as well! Here is the link to the epoxy and the dye kit!
Step 6: Assembly
Glue, hammer, screw, repeat. Starting with the bottom piece down first, we put into place the first side. I think all but one side was a pretty tight fit, which makes for a super strong joint, so we brought out our rubber mallet and got to fitting all the sides into place. We used these finish head screws, so the holes are really small are hardly noticeable.
We added in support pieces in the middle of the box to help with the force from jumping, especially on 30" side. So if you build this, don't forget to add those in while you still have the box pretty open.
Step 7: Sand
After the whole box was completely put together, we sanded all the sides and sanded the overflowed epoxy flush to the plywood face. We brought the box outside to sand, just so so much dust, especially epoxy dust, didn't fill the shop. While the box was still outside, we came around with a chamfer bit from Bits&Bits to take off all the edges. Not only does this look really good, but it'll also help your shins if you accidentally hit them against the box. I may have done this more than I can count back in my soccer training days.
Step 8: Apply Finish
We used Total Boat's Lust Varnish in High Gloss. This varnish is amazing because you don't have to sand in between coats, and you can reapply in 1 hour. We usually will build with the high gloss and then use the Lust in matte to take down the shine. In this case, we did 3 coats of the high gloss and left it because it gives you a little more traction on your shoes, giving you more grip with jumping or stepping.
Step 9: DONE
After all the coats where done drying, we are done! This plyo box came out so good, the heights are perfect for all kinds of jumping and stepping, with or without weights. Our client was thrilled and that's what matters most! Don't forget we do have a free set of plans for you!