Mary, this is the best I can do. My diagrams in word don't seem to copy. Any queries please come back to me:
Cut a one eighth waterproof plywood sheet to the required shape of the base. Remember to leave access for corner steady winders, and transit cover elastics. Don’t interfere with braking mechanism and/or other towbar fittings.
Locate fixing holes in towbar, or drill new ones, and transfer to base sheet. Fit ¾” square reinforcing strips across these mounting holes and drill through size to suit bolt (Mine are 10mm)
Cut out large vent holes if you are going to store gas canisters, or smaller drainage holes if not. Keep them small enough to prevent items dropping out. If in doubt make more small ones. Ensure a suitable route for the gas pipe, and fit supports for gas bottle if required.
Fit a ¾” batten all round edge of base, leaving space for upright pieces. Fix with glue and brass panel pins.
Cut side, back, front and angled pieces to maximum height of finished box.
Attach upright panels with glue and panel pins. Join panels together using ¾” square battens at sharp corners and ¾” x 1½” at shallower corners. These will have to be chamfered to fit shape of box. These battens will allow for rounding the corners after gluing up.
When glue has set decide on a slope for the lid and cut to that shape as near as possible.
Fit a ¾” square batten all round top edge, except at rear where a ¾” x 2½” will be required to support hinge. Plane the top to a level surface.
The lid requires a sheet of thin ply overlapping all round by at least ¾”. Plane pieces of ¾” x 1½” batten to the right angle to match the slope of the lid. Fix to lid with brass pins and glue, and glue all joints where battens meet. Pin or dowel them if required.
Round off all corners to a pleasing curve, sand everything smooth.
Fix hinges to bottom of rear batten of lid, and screw to rear of box.
Paint using primer, undercoat and at least 2 top coats. Rub smooth and apply a good polish.
Bolt to towbar using some foam or other padding, and large washers under heads of bolts where they contact the wood.
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Steve
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I like the odd drink. Five is odd, seven is odd, nine is odd...........
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Topic: Storage Box
