Building a Police Box

Step 4. Make up the pillars

Each pillar consists of a center post [A] and surrounding pieces [B],[B2], & 2 [C]s.

[A] is 90 mmAbbreviation for millimeter which is a metric unit of length equal to one thousandth of a meter. 25.4 mm equals one inch. x 90 mm (3½” x 3½”) stock 2175 mm (87″) long.
[B] is 170 mm x 45 mm (1½” x 6½”) stock 2275 mm (91″) long.
[B2] is 125 mm x 45 mm (1½” x 5″) stock 2275 mm (91″) long.
[C] is 90 mm x 35 mm (1½” x 3½”) stock 2175 mm (87″) long.

Pieces [C] need to be mitred (angled) 45° down one side, and pieces [B] and [B2]need to be shaped (circular edges).

Shape the profile of pieces [B] and [B2]

4.1. Make a 7 mm (5⁄16″) deep cut, lengthwise down the faceThe widest side of a piece of wood. and edge 25 mm in from the corner.

4.2. Make another cut 16 mm (⅝”) in from the corner with the blade setHow much the teeth are angled out on a circular saw blade. on a 45° angle and the blade depth set to 7 mm (5⁄16″) – ending up with a trench the shape of half a V.

4.3. Round the corners of [B] and [B2] with a planer and sand paper to achieve as near as possible a 25 mm diameter round.

Make up each corner pillar of the Police BoxRough grade timber. by joining piece [A] [B] [B2] and two [C]s.
Ensure one pair of corner pillars is made up in a mirror image of the other pair.