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 8. Install the walls, head, and door
Fix one side wall and the front wall
To only one (for the time being) side wall and the front wall (minus the door) add angle brackets, three to each side evenly spaced and a couple at the bottom. Refer to the pictures below.
Fit one side wall (a removable wall, so do not add any glue or permanent fixings) and the front wall (less the door).
The front wall (minus the door) is a permanent fixture so glue can be added.
Drop the head in place
Install the remaining two panels (walls) but first prepare them by adding the angle brackets (fixing brackets that tie the panel to the corner pillars).
Fix the side wall in place without using any glue or permanent fixings so it is removable. Fix the back panel in permanently with both screws and glue.
Fix the top trims
Cut to length and fix the top trims to the tops of the panels with glue and screws.
Note that the two side panels are made to be removable, so take care not to glue the trim to either the head or the side pillars. In other words, just glue between the trim and the panel, as the trim will be fixed to the panel so when the panel is removed the trim will be with it (and not stuck to the head or side pillars).
Fix three 90 mm butt hinges to the door.
Because the screws are going into the sides of the plywood it is a good idea to cover the hinge part against the door with an angle bracket that could be screwed into the side of the door as well as the back face. Have a look at the picture below. The reason? I’m not 100% satisfied with the holding power of screws screwed into the side of some plywood. Then hang the door.