Table of Contents
- 2The size of the thing
- 3About the measurements used
- 4A visual index
- 5Overview of the head
- 6Step 1.1. The head side-frames.
- 7Step 1.2. The head inner support structure.
- 8Step 1.3. The form (mold) for the hypertufa.
- 9Step 1.4. Hypertufa
- 10Placing the hypertufa
- 11Hypertufa - The curing process
- 12Step 1.5. Slurry
- 13Off with the formwork
- 14Step 1.6. The head side-covers and the crown
- 15The crown
- 16Fixing the trim to the side-covers
- 17Step 1.7. Fiberglass
- 18Step 1.8. Paint - undercoating the head
- 19Overview of the body frame
- 20Step 2.1. Shaping the frame members
- 21Step 2.2. Cutting the frame members to length
- 22Step 2.3. Making the wall frames
- 23Step 2.4. The body frame
- 24Step 2.5. The shackles
- 25Overview of the Neck
- 26Step 3.1. The neck - making the box unit
- 27Step 3.2. The aluminum angle for the sign
- 28Step 3.3. Internal perimeter pieces
- 29Step 3.4. Fitting the neck
- 30Step 3.5. The telephone sign
- 31Step 4.1. The trim around the door and window openings
- 32Door and window overview and plan
- 33Step 4.2. Wood for the door and windows
- 34Step 4.3. Joining the stiles and rails
- 35Step 4.4. Notching the muntin bars
- 36Step 4.5. Fixing the muntin bars
- 37Step 4.6. Painting the door and windows
- 38Step 4.7. The acrylic sheet
- 39Step 5.1. Making the base
- 40Step 5.2. Some painting
- 41Step 6.1. Putting it all together
- 42Some strengthening and the door closer
- 43The desired effect
- 44Step 7.1. The rose and ceiling
- 45Making the rose pattern
- 46Marking, drilling, and cutting the rose
- 47Tapering the rose
- 48Painting and fitting the ceiling and rose
- 49The light goes on
- 50The plans
About the measurements used
The dimensions in this project are given in both imperial and metric.
All measurements are given in feet and/or inches first, followed by millimeters (mm) in brackets (). For example: 2″ x 4″ (100mm x 50mm)
For rounding off purposes, the imperial sizes are not an exact match to the equivalent metric sizes.
For example, something built using the imperial (ft and in) measurements will be approximately 1.6% larger than the same item built using the metric measurements. The imperial measurements are more suited to North America. The metric measurements are more suited to Australasia.
Most countries that use the metric system generally put the bigger numeral first, such as 100×50 (mm), whereas those that use the imperial system generally put the smaller numeral first, such as 2″ x 4″ (inches).
Also, both nominations have different finished (actual) sizes. That is, once the wood has been dressed (planed or surfaced).
For example: 2″ x 4″ (100mm x 50mm) when dressed will be more like 1½” x 3½” (90mm x 45mm).
Don’t worry about the irregularities between the two; just use all one or the other.
Overview – the eight chapters
This documentation consists of eight chapters.
The first seven are the seven different stages of constructing the K2 telephone kiosk. Chapter eight is where you will find all the plans.
The seven stages of construction are: the head, the body frame, the neck and sign, the door and windows, the base and a bit of painting, putting it all together, and the ceiling and night light.
I constructed the head out of wood, hypertufa (very lightweight concrete), and fiberglass. I had never worked with the latter two before but found using both to be fun and easy.
The rest of the project was pretty much basic woodworking with a little bit of forethought.
Next is a map (drawing) of the phone box with part identification. From there you can jump straight to information about any particular part of the phone box – a visual index – and that is followed by a step-by-step account of how I made the phone box.
All the plans are in chapter eight, but some will be shown in the appropriate places as we follow the path of constructing a red British K2 Telephone Box.