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Use a saber saw or
circular saw to construct the front, back, and two angled sides out
of plywood. Make the front 9-x-48-inches, the back 15-x-48-inches,
and the two sides 48-inches-long with a slope from 15 to 9 inches
wide.
Using an 18 gauge perforated steel angle, join the side pieces to
the front and back pieces with the angled cut facing upwards. To
attach the angles to the plywood, use ¼ inch hex bolts. Between the
head of each bolt and the plywood, always use a washer.
Now you need to make the frame for the lid. Cut two 8 foot clear
pine 1x3s into four pieces. Two will be 46 ½ inches; the other two
will be 47 ½ inches. With 4 inch steel L-brackets on the underside,
join the pieces together. Flip the lid frame over and cut triangles
from ¼ inch exterior plywood scraps - using four ¾ inch long No. 8
wood screws in each brace, attach the cut triangles to the top side
of the lid frame.
Use three 3 ½ inch hinges to hinge the lid to the box. Using ¾ inch
long No. 8 wood screws, attach the hinges to the underside of the
lid frame first. Then place the lid frame on top of the box and mark
the drilling location for ¼ inch holes on the back of the box on the
outside by using the hinges. To attach the hinges to the plywood,
use ¼ inch hex bolts and washers between the nuts and plywood.
The last step is to remove the hinge bolts from the box and unscrew
the hinges from the lid frame. Number the hinges and mark their
location on the wood frame so that putting everything back together
will be relatively simple. Circle the screw holes in the lid frame
with a bold marker to mark their location as well.
Wrap the lid frame with one piece of 6-mil poly plastic sheeting and
attach with a staple gun or roofing nails.
Put the newly covered lid on top of the box and attach the hinges
again with bolts. |
