Patrol Box Construction Photos

Here are some pictures taken during the construction of the new Patrol Boxes. As you can see the construction is pretty straightforward. Having a table saw, drill and router are recommended. We had to buy a 15/32" router bit to create the dados for the interior dividers and shelves (half inch plywood is not half inch thick anymore). A brad nail gun is also very handy to have during assembly and some large clamps.

See the Patrol Box Plans page for more information on how to get the plans to build your own.

Floor Panel with slots routed for interior dividers.

Center Divider with inset slot to hold a long propane tree.

Extra clearance is required in the notch on the divider to accommodate the piano hinges for the doors.

Shown with the hinge in place.

A brad nail gun is used to hold the pieces together while the glue sets.

Here the lower divider and center divider are in place on the floor panel.

Applying glue with a brush. Note the hole in the panel for holding the propane tree.

Wipe off the excess glue with a damp cloth.

Putting the short shelf assembly on the dividers.

Now the long interior shelf goes on.

Sand the interior parts prior to assembly.

Next come the remaining vertical dividers.

More sanding of the top panel prior to assembly.

Putting glue on the underside of the top panel.

The interior of the carcass is now assembled.

Using more brads to help hold together the parts while the glue sets.

Marking the centers of the dividers below prior to nailing.

The side panels are then added.

More gluing and nailing.

The top panel overhangs the doors. The side panel fits into a recessed slot in the top panel.

More securing of the top panel with brads.

One more side panel to go.

This side panel fits into two shelves.

Marking the centers of the interior shelves before nailing.

Securing the side panel to the interior shelves.

Clamping the top and bottom panels while the glue dries.

Using one of the doors on top to make sure the carcass is squared while the glue sets.

More clamps on the other side.

The completed interior of the patrol box.

More clamps bring the sides together.

There is still more to do. Mount the doors, latches, handles, chain, cut out the brackets for the legs, sand, apply varnish, paint, etc.

Here is a view of the leg bracket assembly.

Order your plans here.