|
To build a homemade sandbox you will need these tools:
Pencil
Putty knife
Electric sander
1 ¼ inch flat drill bit
5/8 inch spade drill bit
countersink bit
1/8 inch drill bit
jigsaw
c-clamp
power drill/ screwdriver
tape measure
crosscut saw
miter saw or block
combination square
You will also need these materials:
Two 4x6-foot sheets of plywood, 3/8 inch thick
20 feet of stock 1 1/8x5 ½ inch
four 6-foot lengths of stock, ¾ x 1 ½ inch
four 6-foot lengths of pressure treated wood, 1 1/8 x 2 inch
No. 6 Phillips-head screws, 1, 1 ¼ and 1 ½ inches long
Plastic pipe 1 ¼ inches diameter, 10 inches long
Foam pipe insulation, 1 ½ inches in diameter, 15 feet long
Quick-drying wood-colored filler
Sandpaper
Water-based stain in assorted colors
Wood adhesive
Nylon rope 5/8 inch in diameter, 12 feet long
Washed sandbox sand
1. Mark a rectangle 36 by 66 inches on one of the sheets of plywood. To make the boat-shaped end, measure and mark 18 inches from the top. Measure and mark the midpoint on he top, then, using a long ruler or length of wood, draw a diagonal line form the midpoint to the marks on each side.
2. Raise and support the plywood above the ground using block of wood or flat stones. The p[plywood should be at least 4 inches above the ground to accommodate the jigsaw. Position the saw blade on the waste side of the wood and cut out the shape.
3. To make the sides of the box, measure and mark two 33 ¾ inch lengths and two 48-inch lengths on the 1 1/8x 5 ½ inch stock. Draw a line across the wood at the marks, using the combination square. Hold the wood firmly and cut each length with the jigsaw.
4. On each side of the longer lengths draw a line ½ inch in from and parallel to the end. Along each side of the lines mark three evenly paced points. Drill a pilot hole at each mark, the countersink each one. Hold one of these lengths at right angles to one of the shorter pieces and fix them together with 1 ½ inch screws. Do the same to the other end. Now turn the structure over and screw the other length of wood into place.
5. Place the four sides on the base and draw a line along each of the inner edges. Now place the base on top of the sides, leaving the end triangle overhanging. Drill and countersink a hole in each corner, then screw each corner to the base using 1 1/2inch screws. Continue drilling pilot holes and adding pilot holes at roughly 4-inch intervals.
6. To make sides for the triangle of the base, set the blade of the jigsaw to a 45 degree angle and cut the end of a piece of 1 1/8x 5 ½ inch stock. Place this cut end on one of the corners of the box and make a mark that corresponds with the apex of the triangle. Draw a line at this mark with a combination square, then make another 45 degree cut along this line. Do the same for the other side of the triangle.
7. Drill and countersink two pilot holes at each end of one of the sides and at one end of the other—you only need one set of screws at the apex. Position the sides of the base and screw them into the sides of the rectangular box with 1 ½ inch screws. Then screw the apex together. Turn the sandbox over and screw through the base into the side using 1 ½ inch screws and spacing them at 4-inch intervals.
8. To make the seat, measure the inside width of the box at the back of the boat shape. Cut a length of 1 1/8x 5 ½ inch stock to length.
9. To make the seat supports, measure and mark 8 inches on a length of 3/4x 1 ½ inch stock. Use a combination square to draw a diagonal line at 45 degrees to this mark so that the longest side of the wood to be cut is 8 inches. Cut along this line with a jigsaw. Cut out another 8 inch length the same way.
10. Drill and countersink two holes 1 ½ inches from each end of the seat support. To position the supports on the inside of the box, measure and mark a line 4 inches up from the base on each side of the box. Position the top of the seat support on this line so that the mitered edge is facing down. Holding the support firmly, screw it in place with 1 ¼ inch screws.
11. For the parasol support, measure and mark the midpoint on one side of the long sides of the seat, then measure 2 inches up from this point. Hold the seat securely and drill a hole at this point using a 1 ¾ inch spade drill bit.
12. Draw a line 8 inches in from the back of the sandbox. Position the seat along this line. Place the flat drill bit vertically in the hole and push it down so its point makes a mark on the base. Take the seat away, raise the base on a piece of wood, a then drill a hole through the base.
13. To secure the seat, drill and countersink two pilot holes 7 1/8 inches and 4 ¼ inches from each end and 1 3/8 inches down from the top of the sandbox. Place the seat on the supports so that the front edge aligns with the top of the diagonal of each support. Fix into place with 1 ½ inch screws.
14. Place a length of 1 1/8 x 2 inch stock on each long side of the base to reinforce it. Make sure that the ends align and then secure them with 1 ½ inch screws. Make sure that you screw into the sides of the box and not through the base. Secure two more lengths on the base and make sure they are evenly spaced and long enough o run to the front of the boat.
15. Using the side of the sandbox to guide the jigsaw, cut off the waste lengths of battens. Cut as close as possible to the side of the boar without cutting into it.
16. To make the holes for the rope handles turn the sandbox on its side and draw a line 2 ¼ inches down from the top edge. On this line, mark six holes at 10, 19, 22, 31, 34, and 43 inches from the end of the sandbox. Use a 5/8 inch spade drill bit and remember to clamp a piece of wood under each hole before drilling to prevent the wood from splitting. Repeat for the other side.
17. To make a support for the parasol, push the plastic pipe into the hole in the seat and down into the hole in the base. Mark with a pencil where the pipe meets the top of the seat. Pull the pipe out and cut along this line with the jigsaw. Push the pipe back into the seat.
18. Position the pipe insulation temporarily so that you can accurately measure the size of the lid. To cut the insulation, insert a utility knife into the top of the indented line that runs along the length of the insulation. Pull the knife toward you to slit the insulation open.
19. Cut miters in the lagging to make neat corners. Place the insulation at the appropriate point in a miter saw and make sure the slit you have cut is at the bottom. Hold the insulation steady, and cut a miter at the end.
20. Starting from the triangle point of the sandbox, pull the insulation apart along the slit and slide it onto one long side. When you reach the middle cross-section, use the utility knife to cut a square to allow the insulation to fit over the cross-section.
21. The lid of the sandbox overhangs slightly o it will be slightly larger than the base. Lay the second sheet of plywood on a flat surface and place the sandbox upside-down on top of it. Trace around the sandbox holding a ¾ x 1 ½ inch stock between the sandbox and your pencil. Cut out the lid with the jigsaw.
22. Using the lid as your guide, measure and cut out five lengths of 3/4x 1 ½ inch stock to go along the underside of the lid. Drill and countersink holes on these lengths of wood at regular intervals. Cut a miter where ends meet. Secure the lengths of wood to the lid with 1inch screws.
23. Drill holes for the rope handle on each side of the sandbox lid using the 5/8 inch spade drill bit. Position the holes 2 inches in from each side and 27 inches and 36 inches in from the back. Remove the pipe insulation from the sandbox and cover all the screws with filler. When it has dried, sand the whole box.
24. Paint or stain the box with quick-drying water based stain or paint in bright colors. When the stain is dry, apply some wood adhesive to the tops and the sides of the sandbox and press the pipe insulation onto it. To make the handles, thread the rope through the holes in the lid and in the sandbox and knot the ends.
| 
