# Materials: Quantity Each: 4x4x8 3 2x4x8 2 2x8x8 1 4x8x3/4 plywood 1 3 x6 corkboard (can be 18 of the 1 x1 pieces) 1 3 x6 plexiglass 1 8 door casing 3 Primer 1 qt. Total Quantity: TIPS FOR SUCCESSFUL PREP WORK: Before starting, carefully read through the entire instruction sheet. Refer to the material list to the left and confirm that you have the correct amount of wood for this project. Instructions below are for one Bulletin Board. Write the number you want to make in the upper left box, then inventory materials by multiplying the Quantity Each by this number. IMPORTANT: Plans are to be used with 3 x6 Plexiglass (SKU #298-017). POSTS, PLEXIGLASS, & CORKBOARD: 1. Sort three (3) 4x4x8s as well as the plexiglass and corkboard. Set aside as these will not be cut. FRAME TOP: 1. Sort one 2x4x8. 2. Measure and cut one 77 length. FRAME BOTTOM: 1. Sort one 2x4x8. 2. Measure and cut two (2) 33 1/4" pieces. BULLETIN BOARD TOP: 1. Sort one 2x8x8. 2. Measure and cut one 80 length.
PLYWOOD: 1. Sort one 4x8x¾ plywood sheet. 2. Measure and cut to 37 1/2" x77 dimensions as shown. CHALKBOARD SURFACE: 1. Sand (if not sanded plywood) and prime both sides of the plywood. CHALKBOARD TRIM: 1. Sort (2) pieces of 8 Door Casing. 2. Cut each to a 77 length. 3. Sort pieces of 8 Door Casing. 4. Measure and Cut 2 (two) 37 1/2 lengths from this one piece. MITER CUTS: 1. Cut 45 degree miter cuts on the far edges of the (2) 77 and (2) 37 1/2 pieces.
FINAL INVENTORY Each Total (3) 4x4x8 Posts 2x4x77 Frame Top (2) 2x4 x 33 1/4 Frame Bottom 2x8x80 Bulletin Board Top 37 1/2 x77 Plywood Sheet 3 x6 Plexiglass 3 x6 Corkboard (or 18 of the 1 x1 pieces) 2 37 1/2" Door Casing 2 77 Door Casing
Materials: Quantity Each: 4x4x8 (Posts) 3 2x4x77 (Top Brace) 1 2x4x33 1/4 (Bottom Frame) 1 2x8x80 (Top) 1 37 1/2 x77 Plywood 1 3 x6 Plexiglass 1 3 x6 Corkboard 1 4x4x8 (Posts) 3 80-lb. bag of concrete 4 Hinges w/ Screws 3 Clasps w/ Screws 2 #10 x 3/4" Screws 20 ea. #10 Nuts 20 ea. 3 Simpson Corner Brackets (A33 or 12 similar) 1 ½ Deck Screws 1 lb 3 Deck Screws 1 lb N8 Simpson Nails 1 lb Chalkboard Paint 2 qts. Exterior Paint (any color for trim) 1 qt. 1 galvanized finishing nails 1/2 lb. Tools: Drill 13/64 Drill Bit ¼ Glass Drill Bit Screwdriver Bit Tape Measure Pencil Hammer Level Utility Knife Glue/Rubber Cement (for cork) Safety Glasses Philips Head Drill Bit 1/8 Drill Bit Paintbrushes/Roller Paint Trays/Cups Total Quantity: FRONT VIEW BACK VIEW Today you will build Bulletin Board Chalkboard(s)! Above is a picture of what your finished project will look like. Follow the instructions below and most importantly, have fun! 1. The Plywood and trim/door casing have most likely already been primed, but if they have not, been be sure to prime them before painting. Paint the trim using the exterior paint, and wait to paint the back of the bulletin board (plywood) with the chalkboard paint until the bulletin board side has been completed. 2. Lay the plywood flat on the ground. You will be constructing everything on top of it to ensure everything lines up correctly. Attach the 2x4x77 to the tops of the three 4x4 posts with 3 screws (2 per connection). There should be 33 1/4" between the middle 4x4 and the outside 4x4 posts (you can use the 2x4x33 1/4" pieces to align correctly).
3. Attach the 2x4x33 1/4 between the 4x4 posts such that the top of that 2x4 is 36 from the top of the 2x4 at the top of the post (and the bottom of the 2x4x33 1/4 piece is flush with the bottom of the plywood piece). 4. Use corner braces and N8 nails to secure the top 2x4x77 piece and the 2x4x33 ¼ pieces to the 4x4 posts. There are 12 corners between 2x4s and the 4x4 posts that need the brackets. 5. Flip the constructed frame and attach the plywood to the square you ve just built, making sure that the plywood is flush on all 4 sides with the 4x4s and 2x4s. Use the 1 ½ screws along all 3 4x4 posts and the 2x4 frame pieces. 6. Use the 3 screws to attach the 2x8x80 to the 2x4 at the top of the bulletin board (above the 2x4x77 ). The 2x8 should overhang all 4 sides of the 2x4 by approximately 1 ½. 7. Attach the corkboard to the plywood on the inside of the bulletin board (between the 4x4 posts) lay out corkboard first then glue to plywood and trim with the utility knife as needed. 8. Attach the plexiglass front to the frame, using the hinges at the top and the clasps at the bottom. The top of the hinges should attach to the 2x8 overhang using the included screws. Pre-drill the holes in the plexiglass with the 13/64 drill bit and attach to hinges using the #10 screws and nuts (nuts facing outward), as shown.
9. Flip the entire structure over to expose the primed plywood on the back. If not already done, paint with the chalkboard paint. Then install the painted trim along all edges of the plywood sheet using the 1 finishing nails. Be sure to orient the trim so that the 45 angles meet at the corners, as shown at right. You may want to drill pilot holes with the 1/8 drill bit to prevent cracking. 10. The bulletin board is now ready to be concreted into the ground. Check with your Build Captain to determine its final location, and then use a post-hole digger to dig the holes for the three posts using the spacing guide below. The holes should be 24 deep and about 8 around. 11. Meanwhile, mix up a batch of concrete in a wheelbarrow (or direct the concrete team to do this). Once the holes are ready, set the bulletin board in the holes and pour the concrete, using a level to make sure the structure is plumb. Also, wipe down any concrete splatters from the posts before they dry. You may want to use scrap lumber, if available on site, to prop up the structure as the concrete sets. 12. Please clean up your work area, and your bulletin board chalkboard is complete! Thanks for all your hard work!