Flying Coffin Project-Box construction

The box itself is fairly simple. Materials are 1/4 inch oak plywood and 3/4 inch by 3 inch and 3/4 by 2 oak planks.

It is frame and panel construction for those familiar with woodworking. For those not, here is a brief introduction.

All About Frame-and-Panel Construction

If you aren’t familiar, then you probably don’t have the tools to attempt this box. I used a large table saw and heavy duty router to machine the parts required. Once all the parts are machined the box itself is assembled by glue and clamping.

The dimensions are as follows.

INTERIOR dimensions of the finished box are 27″ x 60″. This is important because the cockpit floor with the seat assembly must drop into the finished box. So be sure you build the box big enough for the cockpit floor, leaving enough room for the cockpit floor to clear the handle reinforcing blocks when you drop it in.

The long sides are constructed with 3/4 x 3 inch top rails and 3/4 x 2 inch center, bottom and end rails. The short panel separators are 3 inch. These dimensions are purely for aesthetics. You can use all 3 inch or 2 inch or whatever you like for the frames of the sides. 1/4 inch oak plywood forms the panels. You could do fancy raised panels as in cabinets or doors or you could do pierced steel planking for the jungle runway look.

The long sides are 18″ by 61.5″. Ends are 18″ x 27″.

The ends are similarly constructed.

The corners are 1/4″ plywood splines to join them. Here is a photo.

The bottom is open with four cross braces attached to blocks to support the cockpit floor. The 2 x 4 are added to attach the four feet so that the box is elevated off the carpet 2 inches. The feet ride on furniture sliders to prevent floor damage and make the box easy to move.

The box top is constructed in the same manner as the sides expect it is 26″ x 61.5″ and it sits on a frame built of 3/4″ x 2″ parts.

Some detail pictures




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