Build the box beams
This entry was posted on 11/6/2006 8:10 PM and is filed under Setting Up Shop.
The goal for today is to build the two open ended box beams that will be used to make the 24 foot strongback.
Notice the robust sawhorses I made compared to the plastic sawhorses from a home store. Which is better? The plastic sawhorses with an added 2x4 will do an adequate job. The cost is about the same. The time to build is much more than the time it takes to buy. It's your decision.
Notice the new drill on the left. The Bosch drill is really nice and comes with two batteries and a charger. The drill is plenty strong to drive 3 and 3.5 inch drywall screws into 2x4 and 2x6 timbers. I setup the larger drill for drilling pilot holes and the Bosch to drive the screws. What a time saver!
Begin building the box beam by clamping all four 2x6 planks together. Make sure that one end has all butts lined up straight.
Mark the beams every 24 inches. Always use a single tape measure when marking subsequent positions. This will minimize errors.
Notice these 12 foot planks are a bit long. These will get trimmed off so all planks are the same length.
These stretchers were all cut a Lowes. The cost is $0.25 per cut, but they don't charge anything if it is a small number of cuts. I was not charged for these cuts. That is a pretty good deal and saves a lot of time. Tip: Try to have the store do your repetitive cutting.
Check and recheck all stretchers to make sure everything is square. I check top and bottom on both left and right side. Most of the time I get all checks to meet the 90 degree test. But the lumber is not perfect and sometimes you have to fudge just a bit and go for the best fit all around. This corner looks good.
Clamp the end pieces and make sure they are square at both ends. Then begin screwing in 3 drywall screws at each connection point. Use #8 screws 3 inches long. Drill a pilot hole for at least the first 1.5 inch depth. Before driving the screws make sure the stretchers are down all the way onto the sawhorse top and even with the side beams which are also on the sawhorse top. Slide the sawhorse in to the next location and repeat.
When finished the open ended box beam looks like this. Note that the box beam is built upside down. Remember that the stretchers and side planks have to be down flat on the top of the sawhorse? By building upside down all variations in the lumber will be on the bottom side. This beam is ready for linking. Build one more open ended beam. At this point I ran out of screws so the rest will get done tomorrow.
