Table of Contents
- 3Photos of construction part 1
- 4Photos of construction part 2
- 6Plans - Front, floor and footprint
- 7Plans - Base, floor, and wall layout
- 8Plans - Top and roof (millimetres)
- 9Plans - Top and roof (inches)
- 10Plans - The sign
- 11Plans - Details
- 12Plans - Fixed walls - metric
- 13Plans - Fixed wall - standard
- 14Plans - Wall/door - metric
- 15Plans - Wall/door - standard
- 16Materials overall
- 17Framing wood by section - metric
- 18Framing wood by section - standard
- 19Cutting list (frame)
- 20Step 1. Cut the frame pieces to length
- 21Step 2. Rip the relevant pieces to the required widths
- 22Step 3. Make the base
- 23Step 4. Make up the pillars
- 24Step 5. Assemble and stand the frames
- 25Step 6. Make the head (top section)
- 26Step 7. Make the walls
- 27Step 8. Install the walls, head, and door
- 28Step 9. Shape and fix the mullions
- 29Step 10. Shape and fix the decorative pillar top pieces
- 30Step 11. Paint time
- 31Step 12. Make the windows
- 32Step 13. Add the 'police call box' sign
- 33Step 14. Final touches (almost)
- 34Roof lamp Introduction
- 35Roof lamp Plans
- 36Sourcing the components
- 38The lamp container cap
- 39Fibreglassing the cap
- 40The lamp container base
- 41Threaded rod to the cap
- 42Assemble the lamp container
- 43Put in a light or two
- 44The lights go on
Step 7. Make the walls
There are 4 walls. Three of them are identical, while the wall with the door differs.
Each wall comprises of two sheets of plywood – one being the solid backing piece and the other being strips (stiles and rails) glued and screwed to the former.
‘Stiles’ are the strips that run vertically and ‘rails’ are the strips that run horizontally.
Refer to the ‘fixed wall’ and ‘wall/door’ plans for dimensions and follow the instructions below.
Measure and mark on the backing piece panels where the stiles and rails are to go – and from there you can determine the windows.
Mark the window cut-out holes which will be 12 mm (1/2″) bigger (all around) than the window markings.
Cut out the windows with a circular power saw and a handsaw, or a jig-saw.
Cut the stiles, rails, and wall top trims
Cut all the panel stiles and rails including the angles (25°). Cut the stiles to length but cut the rails oversize lengthwise. They can be measured and cut to exact length once the stiles have been fixed in place.
Shape the top trim as per plan. Overall the trim will be 24 mm x 80 mm (1″ x 3¼”) with steps cut in it. Refer to drawing.
Fix the stiles and rails to the backing panels
Note: The stiles are the strips that run vertically and the rails are the strips that run horizontally
Glue the stiles to the panels and hold them there with a coupe of tacks (small nails, pins) so the panels can be turned over without the stiles falling off or moving position during the ‘flipping’ process.
Then screw through the panels into the stiles, pulling all the components tightly together and letting the glue do it’s work.
Flip the panels over again so the face is on top. Then cut rails to fit between the stiles and fix them in the same way as the stiles were fixed. Sand all the panels.
The layout of the panel with the door is different to that of the other three panels. Once this is sanded, cut out the door with a circular saw and a handsaw and sand the freshly cut edges.
These photos illustrate the explanations above.