RIVER ROCKER BOX CONTENTS Detailed Parts List Pg1 Figures and Photos Pg4 Stand Construction Pg6 Rail and Box Construction Pg7 Don't sell or resell these plans. Once something is created it is copyrighted. Copyright 2009 goldohio@yahoo.com REV: 03/30/09 Disclaimer: As with all tools use protective eye and ear ware. The author is not responsible for loss or damage due to use of these plans. We have tried to provide accurate measurements and arranged the plans in a way to be the most useful.Ar P-TACTZOMDWODA River Rocker Parts List | pase: 1/4” x 20th. x 1 1/2” long bolts 3— 1/4” x 20th. x 1 1/2” long tumb bolt (e) 5/16” x 1 1/2” fender washers bh #6 x 11/4” screws co _ #4x3" screws 5/46” allthread cut 14 1/2” long 3/4” notch 16 guage aluminum angle cut 10” long¢ River Rocker Parts List page2 27” x 11” x 1/4” Luan plywood 4” x 3/4” x 6’ piece of wood 2 1/2” x 3/4” x 8’ piece of wood 1 1/2” x 3/4” x 8’ piece of wood 10” x 26” x 1/4” holes - hardware cloth Bottle of tough waterproof glue Aluminum Sheets 6” x 10” 16 ga. or thin Can of waterbase polyurethane satin finish Notes: 1 recommend putting a good coat of waterbase satin finish outdoor Polyurethane on all wood surfaces. Waterbase has less oils that can float your gold. I haven't found any better glue than Gorilla Glue for this type of application. A router is necessary for this project. Tool rental places usually have several types to choose from. Try to borrow some bits as the rental companies don’t rent them. Choose good straight knotless wood, it doesn't matter what kind, | used Pine for my project. The Aluminum sheets can be thin, you can even use other materials, | thought about using thin flat plastic. Please use caution when handling any type of tool. Always wear protective Eye ware and Ear ware. Think Safety First. ‘The authors or any affillates cannot be held responsible for any loss or damages that may occur. This publication is to be used as a guide and a resposible person would get professional training and consult with a woodworking professional before attempting this project.=) 8 2 D 9 % o 3 a i g 9 4 os 9box-open Figure 1 Figure 2 base Figure 3 Figure 4 Figure 5 Figure 6 A rail Figure 7 Figure 8 Figure 9 Page 4Figure 11 Page 5STAND CONSTRUCTION 1.) Cut Two 36” pieces of the 2 1/2’ x 3/4”wood for the legs 2.) Cut Two 10” pieces of the 2 1/2’ x 3/4”wood for the bottom base 3.) Use a router with a 9/32” or (3/8”) plunge bit to cut a hole 18” long on the two 36“ legs starting 11” from the top and ending 6” from the bottom. or? | — W 6" 4.) Measure at nuts maximum diameter, use a drill bit this diameter and drill a hole (countersink) 1/8” deep, one inch from the bottom of each leg. Finish drilling with a 9/32“ bit, insert t nut. 5.) Measure the outside diameter of your PVC pipe, use a drill bit this diameter and drill a hole (countersink) 1/4” deep, four inches from the bottom of each leg, and one inch from the top, finish with a11/32” or (5/16”) hole through the countersunk holes on each leg. ar 6.) Mount the 10” base on the outside bottom of each leg by screwing the 1/4“ x 20 screws in the bottom t nut. Use a squre to line everything up, drill pilot holes an insert three #6 screws in a triangle pattern to secure each base. See Figure 2 7.) Thread the PVC pipe over the threaded rod, insert threaded rod through upper inside holes on both legs, insert fender washers, washers and lock nuts on outside. Same process on bottom. Tighten all nuts. go See Figure 5 Page 6RAIL and BOX ASSEMBLY Aluminum Sheets Start with Four 10” x 6” aluminum sheets Bend Two of the sheets down 45 degrees 2 1/2 “ from one side. These two plates will be the bottom plates. XC" 6 315 degrees \ nd h 112" 10” Bend Two of the sheets down 45 degrees 1 “ from one side flip and bend down 45 degrees1 3/4” from the other side. } 3/4” Top plates iG “315 degrees Page7RAIL and BOX ASSEMBLY 1.) Cut two 26 1/2” pieces using the 3/4” x 1 1/2” wood at 45 degrees. 26 1/2” 2.) Cut two 5” pieces at 45 degree angles using the same wood. 3) 4) 5.) 6) 7) 58 Position Rail as shown and drill a 1/8” hole on center line through the side and bottm rail, use a 3/8” bit to countersink hole about 1/4”. See Figure 7 NC v Apply Glue. Use one #4 3” screw to fasten rail sides to bottom rail using the hole you just made. Do other side and other rail. Lay sides flat to dry. Lay down some wax paper as the glue will stick to anything. Cut two 35” pieces using the 4” x 3/4” wood at 45 degrees. Route a notch 1/2” deep and 1/4” wide on the 27” side. 14" Inside 12" Find the center on the inside and drill using the t nut countersink bit two holes, one 3/4” from top and 2 1/2” from top about 1/8” deep. Use the 9/32” or (1/4”) bit to drill these holes through. or See Figure 6 Page 88.) RAIL and BOX ASSEMBLY Insert two t nuts on the inside holes. Repeat 7 & 8 on other side. 9.) Cut 1/4” Luaun plywood 11” x 27” 10.) Place sides notch side up and notchs facing inside. Wet notch 11.) 12. area and apply glue. Place plywood on top and evenly distribute plywood from ends. Plywood should fit in notch and be flush with bottom. Drill 1/8” pilot hole on center line and inset one sheet metal screw on each side in the middle. Drill more 1/8 holes starting from the inside and working out about every 2 or 3” and insert screws. See Figure 10 Flip over and mount box to finished stand until glue is dry. This will draw the sides out and help keep the sides square to the bottom. See Figure 9 Cut the carpet to size and and place in box. Place bottom alum. sheets in box, place the rails in the box, place the top aluminum sheets in box for a rough assembly. See Fugures 1, 4 Page 9RAIL and BOX ASSEMBLY 13.) Make sure aluminum fits and is not to snug against the sides. Trim if necessary and label each piece. 44.) Press down on the rail and drill a 9/32” or (1/4”) hole approx. 1” from the top of the left side that is also the center point of the rail. See Figure 1 Countersink a t nut on the outside of this side. Repeat this step on the other left side. Bottom Rail Side Tou &tnut 15.) On the Right side press down on the rail and drill a 9/32” or (1/4”) hole approx. 1” from the top of the right side that is also the center point of the rail. No t nuts on these holes. Press 16.) Take out rails and aluminum. On the insides of the right rails countersink at nut in the holes drilled on step 15. Page 1017.) 18, 19.) 20. 21, 21, 22. 23.) 24.) RAIL and BOX ASSEMBLY Place a washer between the outside of the bottom left rail the inside of the side and thread a 1/4” bolt and washer from the inside of the rail and loosly tighten bolt into t nut. Repeate on the top left. Remove box from stand. Hinge up and over the two rails. Wet the wood where the bottom alum. plates go and apply glue. Place bottom alum. plates on rails and drill pilot holes and screw in sheet metal screws, let dry. hint: put wax paper between rail and side of box to prevent the glue from sticking to side. Hinge back over rails into box. Tighten left bolts so hinge will still work. Start on the left side and wet wood where aluminum will go and apply glue. Place left top aluminum sheet on rail and drill pilot holes and screw in sheet metal screws. Wait for the screws on the bottom until screen is installed, oun See Figure 14 XG Bb hint: put wax paper between rail and side of box to prevent the glue from sticking to side. Place three aluminum angle bars across rails, evenly spaced. Place the wire mesh on top of rails. Use sheet metal screws to fasten screen to rails every 2 or 3”. Drill pilot holes in alum. Work your way to the right. Don’t screw the screen on the far right until you have secured the right side aluminum sheet using the same process as in step 19.. Use the thumb screw bolts and a washer to bolt in the right side of the rail to the box. Mount box in stand using remaining tumbscrew bolts. Go get some GOLD, this box also works great for gems. Page 11