Things You'll Need
- 2 pieces of plywood,18-by-24-by-3/4-inches
- 2 pieces of plywood, 24-by-34 1/2-by-3/4-inches
- Wood glue
- Small box of 4-penny finish nails
- Hammer
- Small paintbrush
- 1 piece of plywood, 16 1/2-by-34 1/2-by-3/4-inches
- Framing square
- Compass
- Drill
- 5/8-inch drill bit
- Jigsaw
- 1 piece lumber, 2-by-16 1/2-by-3/4-inches (actual size)
- 1 piece of plywood, 18-by-36-by-3/4-inches
- 13-by-30-inch chicken wire
- Staple gun
- 5/16-inch staples
Instructions
Place the two pieces of 18-by-24-by-3/4-inch plywood on a worktable. These are the sides of the dog box. Put the 24-by-34 1/2-by-3/4-inch plywood on the worktable. These are the box's top and bottom.
Secure the sides to the top and bottom pieces. Apply glue to the 3/4-inch edges of the 24-inch sides of the top and bottom pieces. Butt the glued edges to the 24-inch sides of the side sections and secure them with the finish nails. This results in a box measuring 18 inches tall and 36 inches wide. Label one of the 36-inch sides as the top of the dog box and let it be facing up.
Install the back of the box. Brush glue on all four of the 3/4-inch edges of the16 1/2-by-34 1/2-by-3/4-inch plywood with a paintbrush. Place it just inside the dog box and secure it with the finish nails. The dog box now has a back in it, a labeled top that is 36 inches wide, two sides that are 18 inches tall.
Cut holes in the sides of the box for air vents. Measure down from the top of the box and make a mark on the side of the box at 5 inches. Put the framing square on the mark and draw a line on the side of the box from the front to the back of the box. Measure from the front of the box and make marks on the line at 6 and 18 inches.
Set the compass on 3 inches. Stick the point of the compass on the marks and draw a circle. Drill a 5/8-inch hole inside the circles for the jigsaw blade. Slip the blade in the hole and cut out the circles. Sand the cut edges of the circles with 100-grit sandpaper. Repeat this on the other side of the box.
Secure the box front support between the top and bottom of the box. Stand the 2-by-16 1/2-by-3/4-inch lumber between the top and bottom of the box so one of the 2-inch sides is even with the front of the box. Center it in the opening, but it does not have to be exact. Secure it to the box with the finish nails.
Draw a rectangle on the door of the box. Put the 18-by-36-by-3/4-inch plywood on the worktable. This is the dog box door. Measure from one of the 36-inch sides and make a mark at 3 inches, move the measuring tape over 10 inches and make another mark. Repeat this for the remaining three sides of the door, put the straight edge on the marks and draw lines that are parallel to the sides of the door.
Cut out the rectangle with a jigsaw. Drill a 5/8-inch hole inside the rectangle for the jigsaw blade. Slip the jigsaw blade through the hole and cut the lines of the rectangle to create an opening in the door. Sand the edges of the opening with the 100-grit sandpaper. Staple the chicken wire to the door with the staple gun.
Install the piano hinge to the box and the door. Turn the box on the table so the bottom is facing up. Place the door against the opening in the dog box so that the chicken wire is on the outside. Position the piano hinge on the box so half of it is on the box and half is on the door's edge. Secure it to the box and the door with the screws provided.
Turn the box upright so the top of the box is facing up and the piano hinge is on the bottom. Secure the latch to the top of the box and the door.