Step 1. On the half sheet of plywood, draw twenty (20) trapezoid shaped gussets as shown in Fig A. and B. Cut a notch out of the corner of 6 of the trapezoids as shown in Fig. C. Save the notches.
Step 2. Using either a table saw or a hand plane, ensure that the two 8 foot I x 2s measure 1 3/8Ó the longer side. Next, cut these into twenty 8Õ lengths and eight 3Ó lengths. Depending on what tools are available to you, it may be easier to cut the 1 x 2Õs Into short lengths first and then plane them to the required 1 Ó size. See Fig.D.
Step 3. Cut nine of the 2 x 2Õs to the following lengths: two 6Õ 5 Ó;two 5Õ 10Ó; three 6Õ 11 Ó; and two 6Õ 10Ó.
Step 4. Make an unnotched trapezoidal ÒsandwichÕ using two unnotched trapezoidal gussets and two of the 8Ó 1 x 2Õs assembled as shown in Fig. E. Use a short piece of 2 x 2 scrap to test that the 1 5/8Ó hole Is neither too tight not too loose. This should be an easy slip fit with slight clearance all around. Make a total of six such unnotched ÒsandwichesÓ.
Step 5. Using one notched trapezoid and one unnotched trapezoid, make a half and half sandwichÓ as shown In Fig. F. Make two of these. Take care to make both a left-hand and a right hand sandwichÓ as shown
Step 6. Using two notched trapezoids, make a notched ÒsandwichÕ as shown in Fig. G. Make two of the Make sure that the 1 x 2 sticks up at the outer edge of the notch as shown in Fig. G.
Step 7. Take the two 2 x 2Õs that are 6Õ 5 3/4Ó long from Step 3, and four of the unnotched ÒsandwichesÓ from Step 4, and make the two Side Pieces shown in Fig. H.
Step 8. Take the last two unnotched ÒsandwichesÓ from Step 4 and one of the 6Õ 11 3/4Ó long 2 x 2Õs and make the Bottom Rear piece as shown in Fig. J.
Step 9. Take the right-hand and left-hand ÒsandwichesÓ from Step 5, and one of the 6Õ 11 3/4Ó long 2 x 2Õs and make the Top Rear piece as shown in Fig. K.
Step 10. Take the two notched ÒsandwichesÓ from Step 6, (Fig.G.) and the last of the 6Õ 11 3/4Ó long 2 x 2s and make the top front piece as shown in Fig. L
Step 11. Take the four 2 x 2Õs which are 5Õ - 10Õ and 6Õ - 10Õ from Step 3 and designate them Rear Posts and Front Posts respectively. Take four of the 3Õ long 1 x 2Õs from Step 2, and nail one of them to both kinds of these posts 5 Ó from the top as shown in Fig. M.
Step 12 Take the small notch pieces that you saved from Step 1. And Cut them in half (a hand saw is safest for this cut), so that you now have pieces that are approximately 1 Ó x 1 1/8Ó You should make a total of six such pieces. ItÕs also OK to use scrap wood and leftovers.
Step 13 Take two of the three remaining 8Õ long 2 x 2 s, stack up three small notch pieces and nail onto the end of each 2 x 2 as shown in Fig N. You now have only one 8Õ long 2x2 left untouched.
Step 14. If you followed the instructions when doing Step 2, and taking into account the width of the saw blade you should have a leftover piece of 1 x 2 about 6Õ long Cut this into three equal pieces. If you donÕt have such a piece, find some old scrap that will do and cut it into 2Õ pieces so that there are three pieces that measure Ó x 1 Ó x 2Ó
Step 15. Nail the three pieces onto the last 8Õ long 2 x 2 as shown in Fig P.
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