- 1). Measure out the desired dimensions of the truck box on the plywood using the framing square. Be sure to cut the bottom panel first, then cut each successive piece to fit accordingly.
- 2). Glue the sides to the bottom after you have cut them out. Adjust the bottom size according to how big you want the truck box to be.
- 3). Coat all mating surfaces with the epoxy. Once all surfaces are coated, fix them in place and allow them to dry overnight. Use the clamps to hold the pieces in place for the glue-up. Apply epoxy to all the inside corners of the box, which will strengthen the box and make it more sturdy.
- 4). Place 3/4-inch cleats around the top inside of the box and glue them to allow for a proper glueing surface for the top panel of the box.
- 5). Fit the top panel in place and glue it on, then place weights on top and let it sit overnight.
- 6). Using the saw, carefully cut a door opening in the top and glue 3/4-inch cleats around the inside perimeter. Next, apply coamings around the established perimeter and coat them with epoxy.
- 7). Use a jigsaw to cut the door panel out of the remaining plywood. Afterward, glue on the door edges. Be sure to leave 1/16-inch space all the way around so it will be easy to open and close the door. Sand and round out the edges, then apply epoxy to them and allow the epoxy to dry.
- 8). Install a spacer cleat and the brass piano hinge for the door panel. Finish the truck box by sanding and filing off rough edges of fiberglass tape if necessary, then wash the box with soap and water. When dry, paint it with a wood stain if so desired.
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