Introduction: Plyometric Box (700 X 600 X 500)

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I fancied a change up to my training, seen plyometric boxes and decided to give making one a go after seeing the below guide.

https://www.artofmanliness.com/articles/how-to-mak...

I definitely made a few mistakes but I will hopefully point them out before you make the same ones.

Supplies

  • A sheet of plywood 2.4m x 1.2m x 18mm
  • Pencil
  • Speed square
  • Measuring tape
  • Router
    • Flush trim blade
    • Rounding blade
  • Jigsaw
  • Drill
    • 3mm bit
  • Mallet
  • Handsaw
  • Circular saw
  • Clamps
  • Level
  • Screws (4.2 x 60mm)
  • Wood glue
  • Wood chisel

Step 1: Cut Your Sheet to Size

You'll need to cut your single sheet into 6:

    A= two sheets 600mm by 500mm

    B= two sheets 700mm by 500mm

    C= two sheets 700mm by 600mm

    If possible, get the timbre saw at the local hardware store to cut your sheet if possible. This will save time and effort. Otherwise cut the sheet into 3 lengths of 1.2m wide measuring 700mm, 700mm and 500mm using your circular saw.

    1. Mark the sheet at 700mm
      1. Tip: Use the spirit level as a guide
    2. Measure the distance from the edge of the circular saw plate to the blade.
      1. Set your level this distance from the mark
    3. Clamp the sheet and spirit level in place
    4. Rip your sheet
    5. Repeat steps 1-4 for two more sheets (700mm and 500mm)
    6. Cut your three 1.2m sheets using steps 1-4 to 700mm by 600mm, 700mm by 500mm and 600mm by 500mm
    7. Label each sheet A1,A2,B1 and so forth

    Step 2: Cut Out All the Box Joints

    It might be overkill but I went for box joints and screws (just in case).

    1. I found it useful to take a length of scrap plywood and use it to draw around the edges of all 6 sheets to get one sheets width (18mm) from the edge.
    2. Hopefully the attached plan makes sense
    3. Mark the A1 and A2 sheets first (Make sure to label the cut outs properly to avoid the mistake I made)
      1. Use the hand saw on all the cut lines (18mm in from the edge)
      2. Use the jigsaw to cut out each section just below your pencil line
      3. Use the wood chisel and mallet to square up your cut outs (easier said than done)
    4. Now take the B1 sheet and align it with one of the 500mm sides of the A1 sheet
      1. Use the A1 as a template to mark the cut outs on the B1 sheet
      2. I found it useful to write A1 and B1 on the corresponding joints on the opposing sheets for when it is time for construction
      3. Cut out the marked sections
      4. Repeat on the opposite side of the B1 sheet using the A2 sheet and cut out.
    5. Repeat step 3 to mark the 600mm sides of B1 and B2
    6. Use A and B sheets to mark and cut the C sheets

    Step 3: Assemble and Smooth

    1. Gather all six pieces
    2. Dry assemble to check if the joints make a good fit
      1. I found adding one of the A sheets last the easiest
      2. This may require a tap from your mallet
    3. Now is the time to tidy any joints with your chisel
    4. Once happy with your joints pilot drill (3mm bit) and counter sink for each screw placement (5 dozen or so)
    5. Dismantle the box
    6. Assemble the box again adding glue to each joint (wipe away excess glue)
    7. Screw the joints together. Making sure of a tight fit (its mallet time again).
    8. Once the glue is dry use the trimming blade on the router to smooth any overhanging joints (best done outside or with good ventilation)
    9. Now use the rounding blade on the router to smooth all corners. The bigger the rounding blade the smoother the box will look and feel.
      1. Note: screw placement stopped me from using my bigger rounding blade.
      2. Check before you run over any screws too lose to the edge with the router.