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Materials: 1) sheet 3/4" CDX plywood
(2) sheets 3/8" CDX plywood
(2) sheets 1/4" Masonite
(7) 2"X4"X8' lengths Douglass Fir or Hemlock
(1) 5 lb. box of 2" drywall screws
(1) 5lb. box of 16D green vinyl checkered head nails
*Saw horses make cutting easier and safer
Tools needed:
Power hand saw (magnesium wormdrive "skill" saw)
Hammer (pref. 24 oz. framing hammer)
Chalk snap line
Tape measure (25' with 1" blade works best)
Drill or electric screwdriver
*Read ALL instructions BEFORE starting to build! If you don't know what something is or how to do something, ask! Remember, safety first.
Step 1
>>> Measure up 52" on both 8' sides of your 3/4" plywood. Snap a line across the wood at these points, and then cut the wood in two along that line.
Step 2:>>> Take the 52" piece of ply and snap lines every 11" so you end up with lines marked for (4) 11"X52" pieces of ply, and (1) piece of 4"X52" scrap on the edge. Cut the wood into those pieces.Step 3:>>> On each of the 11"X52" pieces of 3/4" ply, measure 18" up on side of the 52" sides and make a mark there. From that mark, snap a line to the corner on the opposite side of the board at the opposite end of the side you began measuring from. You should see the shape of the bank and part of the flat deck. Measure, mark, and cut all (4) of the 11"X52" ply pieces into this shape so you have both side walls of the banks and flat deck.
Step 4:>>> Cut your 2"X4" lengths down into (14) 32 1/2" lengths. These will be the frame supports which hold the side walls together and support the structure. Step 5:>>> For help see Diagram A) Take two of your bank/flat plywood pieces and (7) 2"X4" lengths. Connect the (2) wall pieces with the 2"X4" pieces at the following spots on the wall pieces: (1) with the 2" edge flush with the edge of the ply just past where the deck area starts; (1) with the 2" edge flush with the edge of the ply at the top back corner of the deck portion; (1) with the 2" edge flush with the edge of the ply at the bottom back corner (on the ground) of the deck portion; (1) with the 4" edge flush with the edge of the ply as close to the tip of the bank portion of the ply without sticking up; (1) with the 2" edge flush with the ply edge just before the bank portion becomes the deck portion (the bottom of that 2"X4" should touch the bottom of the 2"X4" edge behind it (the one at the beginning of the deck portion); and then stagger (2) 2"X4" pieces spaced evenly between the 2"x4" at the top of the bank portion and the 2"X4" piece at the bottom of the bank portion. Repeat these 2"X4" attachment steps for the other (2) bank/deck pieces of ply and the other (7) pieces of 2"X4" so you have two of the same forms.
Step 6:>>> Using the other portion of the 3/4" plywood you didn't cut into strips, cut (1) 34"X42" piece. This is the plywood piece for the deck of the structure. Step 7:>>> Using the other portion of the 3/4" plywood you didn't cut into strips, cut (1) 34"X42" piece. This is the plywood piece for the deck of the structure.
Step 8:>>> Using the 2" screws, screw down the 3/4" deck ply onto the 2"X4" pieces in the frame of the bank/deck forms. Step 9:>>> Take (1) of your 3/8" plywood sheets and cut (2) 34"X37" pieces from it. Place (1) on each side of the bank (these are your first layer of the bank surface. Be careful to line up the edge of the bank ply with the edge of the deck ply; you don't want to have a gap.)
Step 10:>>> Using the 2" screws, screw down both pieces of the bank ply to the 2"X4"s in the frame of the bank.Step 11 :>>> Take the other sheet of 3/8" plywood and cut (2) 34"X38 1/4" pieces. These will be your second layers on the bank. Place (1) on each side of the bank, on top of the first layer, being careful to again line up the edge of the bank ply with the edge of the deck ply. The bottom of the second layer of the bank ply should stick out about an inch beyond the first layer, staggering the layers to help the transition from flat to bank.
Step 12:>>> Using 2" screws, screw down the second layer of bank ply into the 2"X4"s under the first layer. You may want to snap lines across where the 2"X4"s are before you start screwing the wood down. Make sure to get the top edge of the bank ply as level as possible with the edge of the deck ply otherwise you will have a lip on the deck. You don't want that...
Step 13:>>> Take (1) piece of Masonite and cut (1) 34"X43" piece from it. This is for the top layer of the deck. Align it so a small portion of the 34" sides are sticking out over both points where the bank ply meets the deck ply on either bank, so it covers the seam there. Using 2" screws, screw the Masonite down into the 2"X4"s below the ply layer. Again, you may want to snap lines across the Masonite first to show you where the 2"X4"s are below. Pre-drilling the holes is also a good idea to keep the Masonite flat over time.
Step 14:>>> Take the other sheet of Masonite and cut (2) 34" X 39 1/2" pieces. These will make the final layer on the banks. Line up the top edges so they fit flush against the edge of the Masonite on the deck and the bottom edge extends about an inch past the edge of the second layer of ply.
Step 15:>>> Using 2" screws, screw the Masonite down to the 2"X4"s below (snap suggestion again applies). Repeat for the other bank.Step 16:>>> Using 2" screws, screw the Masonite down to the 2"X4"s below (snap suggestion again applies). Repeat for the other bank.
Hints:>>> If you aren't familiar with power tools, GET HELP! You really don't need to be playing "surgery" with yourself. Once the wood is measured, marked, and cut, label each piece to avoid confusion during construction. Use sand paper to smooth out any lips where the Masonite pieces join together.
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