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Old 02-19-2013, 06:48 AM   #1
Steve Agocs
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Rounding the edges of wood plyo box? Yes or no?

A buddy of mine made me a pretty nice 20"/24"/30" plyo box from what looks to be 3/4" pine plywood (real plywood, not particle board). The edges tend to splinter off and they are really sharp because he planed them down to be dead flat with the surface of the box on each side.

I was thinking about putting a slight radius to "knock off" the edges to reduce the amount of splintering, make it more shin friendly if I ever decide to mess up a jump and clean up the look a little. I know the devil is in the details, so I wanted to see if there was a reason not to do this before I go for it.

On a side note, I used an online stencil printing service to make number stencils and found a stencil to use for a spartan design. Looks pretty cool, although the paint wanted to bleed in the plywood and paper isn't the best stencil mask. Overall not bad, plus the thing is for jumping on, not looking pretty! LOL
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Old 02-19-2013, 07:37 AM   #2
Stephen Hull
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Re: Rounding the edges of wood plyo box? Yes or no?

I used a router to put a nice curved edge on my 20x24x30. Just go slow the first pass and it should be fine.
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Old 02-19-2013, 08:38 AM   #3
David Allen Rogers
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Re: Rounding the edges of wood plyo box? Yes or no?

I used a sander to make smooth rounded edges on mine and it worked fine.
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Old 02-19-2013, 09:22 AM   #4
David Tran
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Re: Rounding the edges of wood plyo box? Yes or no?

I have a plyo box from Muscle Driver and the edges have all been rounded out. Seems to work fine for me.
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Old 02-19-2013, 11:34 AM   #5
Steve Agocs
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Re: Rounding the edges of wood plyo box? Yes or no?

Great, thanks for the replies! It didn't SEEM like there would be a problem, but I tend to be one of those, "OHHHHhhh, THAT's why I shouldn't have done that...." people.
ops:
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Old 02-19-2013, 03:06 PM   #6
Matt Davies
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Re: Rounding the edges of wood plyo box? Yes or no?

I rounded the edges on mine with a palm sander.

Since I built the angle sided ones, no opportunity to flip flop for different heights. I installed dinoflex flooring on the top, great traction and a nice rubbery edge so no splinters on the shins.
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Old 02-20-2013, 09:21 AM   #7
Matt Hemphill
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Re: Rounding the edges of wood plyo box? Yes or no?

I made a very similar box out of 3/4" plywood and routered the edges and then sanded with a pad sander. Has worked good so far.
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Old 02-20-2013, 09:30 AM   #8
Christopher Morris
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Re: Rounding the edges of wood plyo box? Yes or no?

Quote:
Originally Posted by Steve Agocs View Post
Great, thanks for the replies! It didn't SEEM like there would be a problem, but I tend to be one of those, "OHHHHhhh, THAT's why I shouldn't have done that...." people.
ops:
The only problem I could imagine is if your bevel cuts into the edge so far that you're hitting the screws that hold the sides together. That would be more rounding than you'd ever need. I'd say round less than half the width of your 3/4" plywood. Even a 1/4" bevel would be enough to save your shins.

On the stencil - try using contact paper next time. It will glue down to prevent bleeding, but the glue is weak enough to peel off after the paint is dry. Each stencil is a one-time use, but if you're printing your own, that's not a big deal.
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Old 02-20-2013, 09:40 AM   #9
Steven Nedorolik
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Re: Rounding the edges of wood plyo box? Yes or no?

Once I built my box, I finished the edges with a rasp. Its a cheap alternative if you don't have a sander. I found a set of 3 for about $10. Smooth it out with some sandpaper afterwards.
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