Recently I have been weight training for the baseball season and while working on speed and agility I realized I didn't have anything to do box-jumps and step-ups on so I did some research to see what a plyobox would cost to buy, and theses things tend to cost anywhere from $80-$120. So I figured that I could make one of higher quality at a lower price, so that is exactly what I did.
Step 1: Materials
- Straight edge
- Sand paper
- Spray paint - $1 (they have great $.96 spray paint at Menards)
-1/2" wood screws 3pk- 12×$.86= $11
* The spray paint isn't needed unless you are going to spray paint the box like I did, and if you want to put words on the box like I did you can pick up 6" stencils at lowes in their mailbox/house number aisle for around $8
Step 2: Measuring and Cutting the Sides
The first picture shows the design I am going off of to build this project, and as you can see this is a 20"×24"×30" plyo box. For this project I accidently bought 4'×8' plywood sheathing which means it has a 1/4" groove in each of the sides so If you find that you have also bought plywood sheathing just make sure you take that into consideration and make your measurements an inch from the edge like I did. Now it's smart to measure and cut your big sides first and theses would be be your top and bottom sides which are 24"×30", so mesure and cut these sides. Now proceed onto your next biggest sides which are your front and back sides that are 20"×30" in dimension, measure and cut these. For your last sides which are 20"×24" cut and measure these.
Step 3: Measure the "Puzzle Piece" Sides
As you can see I designed this box to fit together with a knotch and groove design, which gives it a nice look but also plays into the structural integrity of the box which makes this box super sturdy. Make sure you make these knothces on all four edges of each side. On the 30" Sides make marks at 10" and 20" then measure 3/4" into the box and then draw the reciprocal shapes on each of the edges as shown in the pictures. on the 24" edges draw your marks at 8" and 16" from the edge, and on the 20" edge make your marks at 6 1/4" and 12 1/2" from the edge.
Step 4: Cutting the "Puzzle Pieces"
Now it's time to cut out your edges, this step is pretty self explanatory if you follow the pictures and cut along the lines. one thing I should mention is that when you are cutting out the sides with the internal cut, the best that I found to cut the edges is cut at an angle then go back and cut the angle out (as shown in the pictures above). Make sure you give each one of the edges a good sanding to cut down on the sanding you will do in the end.
Step 5: Measuring and Cutting the Handles
Start by assembling the box to make sure all the Pieces fit together flush, if not make sure you make those changes now. To draw the outlines of the handles I measured 15" from the bottom of the box and make aline 8" long then I used a small airosol can as a stencil to make the rounded edges, as shown in the pictures above. Now connect the top of the circles, and do the same to the other side.
*Make sure you make these handles on the 20"×24" Sides
Now to cut out the Handles you need to first make a small pilot hole, I used a 1/8" drill bit, so that your jigsaw blade can fit into the wood. make sure to take this cut slowly, especially around the round edge to ensure a nice looking handle. Also this is one of the most important parts you need to sand down because this is how you will carry the box and it's not the greatest feeling to get an inch and a half long splinter stuck in your hand... and yes, that really happened. So just make sure you sand these handles down good.
Step 6: Assembly
Now that you have cut out the handles you can assemble the box. Make sure you drill pilot holes for the screws, I put two screws per joint. As you can see in the picture above I striped the you know what out of one of the screws. I would advise you not to do this but if this does happen to you, you can take some pliers and manually unscrew it from the box. Once you have screwed the screws into all the joints make sure to give all the corners a very good sanding because if you mess up on a box jump you don't want to bust your shins on 3/4" plywood (it doesn't feel too good)
Step 7: Painting
This step is optional but it gives your box a sense of style. If you decide to paint your box, first take your stencils and useing masking tape connect the stencils (making sure to cover up any holes in between the letters). When you are painting the box make sure to spray in quick bursts, not drenching the stencils with paint ( if you drench the stencils in paint, the paint will bleed beyond the stencils and the box will loose it's clean apearance). If you didn't wear gloves like me and you end up with half the can of paint on your hands, there is a quick fix to get it off. Just pour some mineral spirits onto a rag and the paint will rub right off.
Step 8: Finished
Now that you have completed the box you can now do your plyometric workouts any where you can bring this thing. This was a very fun weekend project that anyone with a little bit of woodworking expirience can make. Remember, if you liked this project check out some of my others, and don't forget to follow. Thanks.