Saturday, November 8, 2014

Build Your Own: Solid Bottom Board

This one is a little trickier than the Screened Bottom Board. It is reversible featuring both a 3/4" entrance as well as a 3/8" entrance. For this project you need a piece of pine at least 59 5/8", or similar scrap at a width of 1 7/8". In addition it uses 3/4" exterior plywood. Using all new material and my personal favorite 7/8 rough pine, you can save a great deal of money on bottom boards. To give you an idea.

Makes 12
Exterior Plywood 3/4" - $36.52 (Home Depot)
Rough Pine 1'x12'x1" -$13.80 (Home Hardware)

Not including tax we can make 12 solid bottom boards for $50.34, or $4.20 a piece.

Step One

Begin by making your rails. The stock dimension of lumber we are using is 1 7/8" by 7/8" thickness. We will begin by creating the dado (or groove) which will secure the plywood floor. The is best done using a dado blade on a table saw, or a router. If you lack either of these simply make multiple passes with your table saw until you achieve our 3/8" by 3/4" groove (might want to clean it up with a chisel.

Step Two

Now simply cut the rails to the required length using a chop saw.

Step Three

Now its time to rabbet the back rail. By doing this it creates a much stronger joint and overall bottom board. They do have to carry quite a bit of weight. Take the shorter piece of rail 16 5/8" and using the same method as you created the groove for the rails, rabbet out 7/8" on each side.

Step Four

Next job is to cut the plywood. No matter which way you cut it you will get 12 bottom boards out of a 4x8 sheet. Dont over think it. It is helpful to have a friend around to help with the cutting/moving as the first cuts will be awkward by yourself (no worries the cut edge is hidden anyway). Begin by ripping the plywood to the dimensions above.

Step Five

Assembly is rather straight forward. Glue and nail.

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