Project: Plywood Forklift Part 3

The Real Deal

Our scale model and interesting slice tests all passed so we’re ready to cut the actual project. This cutting part is uneventful so we’ll fast forward past that. The only change we made was to stop wasting our compression spiral, a pricey bit, on cutting OSB. We are trying an Onsrud 52-910, a two flute upcut spiral.

All the Parts

To make assembly faster, we stack parts together by type. We have not cut labels in them or written down any instructions.

Assembly

1 Start with the interior frame first, Int X and Y’s.

2 Add X/2’s to middle of the Int Y’s. Y Ribs with tabs go in the middle of each side.

3 Remaining Y Ribs fill the slots in the Int Y’s.

4 Install two X Ribs with tabs in middle of Int X’s.

5 Remaining X Ribs fill the slots in the Int X’s.

6 Install Ext Y’s to lock X Ribs

This is easier if you start with the piece angled with the bottom edge out from the Int Y but with top edge under the X Rib tabs. As you slide the Ext Y part into place it will lift the X Ribs up and lock them.

7 Install Ext X’s

8 Place Top Face - tabs hold it in place

This completes the torsion box design and provides extra strength.

Next

With assembly complete, we need to finish the project with glues or screws and add six heavy duty casters.