I had a bunch of pallets and I thought they would make great wood to make an old-looking coffin. Here is what DH and I have gotten done so far. It will eventually be a MIB pneumatic. When I get to that stage I will start another thread. OK, here goes my first tutorial:
To make this I used 4 pallets (2 small and 2 large) to give me enough wood for the top and sides. I used a sheet of plywood for the bottom and a box of 1 inch dry wall screws (coarse thread) and 3 (6 foot by 6 inch) fence posts. I used a drill, marker, angle saw, reciprocating saw, and circular saw (also my jig when the battery on the circular saw died.)
Use a reciprocating saw to cut off the nails from the pallets to separate the boards.
Lay out the best narley pieces of wood to make your lid. Mine is 6 feet long and 27 inches at the widest point.
To make three cross braces (top center and bottom): Take a 6 foot, by 6 inch fence post ($1.50 at Lowes) and cut down the center to give you two 3 inch fence posts Now measure the top, bottom and center of the lid and give yourself a 2 inch clearance on each side. Cut three braces (one each for top, middle and sides) with saw.
At the top, bottom and middle: slide a section of the fence post underneath. Leave a 2 inch space from all sides.
Pre-drill holes (2 for each board) and screw in 1 inch drywall screws.
Flip over and add another cross brace for stability.
You will now mark the outline of the toe-pincher. For the bottom angle: Take a long board and starting 16 inches from the top and 3 inches from the edge of the bottom, mark a straight line. Repeat for the other side. For the top angle: start at that same 16 inch mark and 3 inches from the edge of the top side, make a mark. Repeat for the other side.
Now cut off to form the shape of your coffin.
You must make sure that the braces give you enough clearance for the sides when you close it. If too long, cut off with a saw.
Continued in next post.....