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Old 07-28-2008, 01:30 AM   #1
Kevin Steel
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making different plyobox sizes

im making some plyoboxes of different sizes. im using the instructions from the cfj article 49, which gives you the measurments for a 20in box(23.5 width base/ 17.5 width top/ 18.5 hight walls/ 75.5% incline. i want my boxes to be the same as the "store bought" professional ones( i dont want goofy looking boxes). here is my dilema-

as you increase or decrease the size of you box, it will not always be to scale as the original 20in plans (since a 24in box is 1.2% taller than a 20in box, i tried making the base 1.2% larger as well to keep the 75.5% angle for the top, and the whole box was way bigger than what it should be)

so the question is- since at the moment im trying to make a 24in box, should i 1)keep the base and incline the same as the 20in plans (23.5/ 75.5) and settle for a smaller area on the top. or
2) keep the base the same but increase the angle so i have a little more area up top but the walls will be straighter. or
3) keep the top width(17.5in) and the angle the same, making the base a little larger. or
4)mixture of the above or other?

so i gues the real question to the people who have bought the sets of plyo boxes is; is the top surface area the same on all the med sized boxes(18,20,24)? does the angle appear to be the same on the different boxes?

hope this makes sense
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Old 07-28-2008, 05:19 AM   #2
Richard Sharpe
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Re: making different plyobox sizes

I too have wondered the answer to your question. I am looking forward to an answer.
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Old 07-28-2008, 11:35 AM   #3
Carl Woodward
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Re: making different plyobox sizes

IMO you should keep the tops equal size, the angle the same and grow the base...you do not need much oc an anlge..~6 degrees or so. This will keep the boxes "stackable"...if you change the angle much, they will become hard to stack. I was able to get a 20" box and a 24" box out of a single 4'x8' plywood sheet. See the attached plans...each box is about .75" short to account for a .75" rubber mat top.
Attached Files
File Type: pdf plyo.PDF (23.6 KB, 1167 views)
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Old 07-28-2008, 12:00 PM   #4
Jeff Yan
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Re: making different plyobox sizes

Perhaps consider making a 20" box and a 4" riser.
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Old 07-28-2008, 12:37 PM   #5
Kevin Steel
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Re: making different plyobox sizes

I guess im going with option number 3 then. Thanks Carl, thants a nice diagram, way better than mine.
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Old 07-28-2008, 09:16 PM   #6
Brett Miller
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Re: making different plyobox sizes

i made my plyo boxes from the same cfj article. however after making my first 20", i decided to scale everything down because they were kind of big. i made a 12",20",and a 4" riser. and they stack on top of each other. the easiest way in my opinion is build a 4" riser. but if you want a 24" box, here are my dimensions for mine. top should be 15.5" square with 10 degree taper cut. I use a table saw. 2 sides should be top - 14 and bottom -22. the other two sides should be top 15.5 and bottom 23.5. my dimensions allow for 3/4 inch stall mat to be placed on top for cushioning. all tops and bottoms should be tapered to a 10 degree angle. this gives your boxes the slope you need so you don't scrape your knees. also the 10 degree angle gives you optimum support value. http://http://www.board.crossfit.com...1&d=1217304972

the height of each side should be 22.5 inches tall.

Last edited by Brett Miller : 09-14-2009 at 10:00 AM.
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Old 07-28-2008, 09:35 PM   #7
Kevin Steel
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Re: making different plyobox sizes

Well I cut the wood today. what a pain in the a**. i used an old table saw that had a not so striaght guide fence. ripping down the 8' board was a nightmare, even with someone assisting. the last time i used a table saw was in high school where they had a 10 ft long table to hold everything. but, i think its going to come together nicely. made a 20 and a 24, and used a 7degree cut. thanks guys.
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Old 07-28-2008, 10:01 PM   #8
Jeff Yan
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Re: making different plyobox sizes

I just started making boxes myself. For me so far, the worst part is the measuring.

I'm using a circular saw.
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Old 07-29-2008, 05:48 AM   #9
James Reynolds
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Re: making different plyobox sizes

Quote:
Originally Posted by Jeff Yan View Post
I just started making boxes myself. For me so far, the worst part is the measuring.

I'm using a circular saw.
I made mine with a circular saw as well, and found it's pretty easy to make a "not quite perfect" cut - so keep that in mind if you aren't a pro with it

Here's a WFS link to a photo album I made of my build.

I still haven't found anything that would work for a rubber top.
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Old 07-29-2008, 07:54 AM   #10
Justin Lascek
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Re: making different plyobox sizes

I helped make some this weekend, and we kept all of the tops the same size and adjusted from there. I'm about to go sand them today.

If you need anymore dimensions or clarification, let me know.
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