Plyo boxes and lessons learned
I built these 4 boxes from 2 and 1/4 pieces of 4 x 8 plywood. I'm guessing I could have built 1 more from what I had left so 3 pieces would easily build 5 boxes.
I used the awesome instruction from CFJ #49. I would add the following:
1. Have a helper. No way you could hold these together to screw and glue your self. I used Elmer's Wood Glue.
2. Mark a template on your work surface for pre-drilling the side's screws-that way they all look even and the same.
3. I used 1 1/4" deck screws instead of drywall screws, they're only $2 more for the 1# box.
4. For the handles I used a 2" hole saw on my power drill to cut the rounded ends (with minimal overlap on the marked centerline) and then used the jig saw to cut out the little piece left in the middle.
5. Definitely make the cardboard mockup. I though that helped alot. I still measured out the pattern on the plywood using a drywall square but making the cardboard on helps visualize how the cuts should look.
I'm gonna jump on them as is and wait until it's a little warmer outside to sand them, varnish and put the mat on top.
All in all a doable project with modest carpentry skills. I'd guess about 5 hours all together as they are.