Here is the Material List:
All lumber is type Douglas Fir #2 or better
MATERIAL USE
FOR:
2 each - 2” x 6” x
12’ (Bunks)
3 each - 2” x 4” x
12’
(Longitudinal base frame members, bunk risers)
(Longitudinal base frame members, bunk risers)
1 each - 2” x 4” x
10’ (Center cross members)
1 each - 2” x 4” x
8’ (End cross members)
3 each – Plywood
Panels ¾”x 24” x 24” (Gussets)
1 box - 3” Gold
Screws
1 box - 2” Gold Screws
16 - 3/8-16 x 1
1/2” Hex Head Bolts
16 - 3/8-16 Hex Nuts
32 - 3/8 Flat
Washers
4 each - 5”x2”
Swivel Castors Harbor Freight #38711
Here is the Cut List:
Bunks - Cut 2x6x12 down to 11’-0” 2 each
Bunk Risers-Cut 1 of the 2x4x12’ into 12” lengths 10 each
Base Frame
Longitudinals – Cut 2 of the
2x4x12 down to 10’-9”
Base Frame Center
Cross Members – Cut down to 38” 3 each
Base Frame End
Cross Members – Cut down to 41” 2 each
Base Frame Gussets
– Cut each 24”panel diagonally in half 6 each
Set up all materials – Check
for proper cuts, inventory parts.
There are 4 parts
in this project: 1) Base Frame 2)
Bunk Risers 3) Castors 4) Bunks
Base Frame
1) Setup base
longitudinal members on floor
2) Layout measurements
for center cross members. From rear measure 31 ½”, 63 ¾”, 96”, and mark with a
framing angle. This will be the face mark for the cross member from the rear.
Check for equal distances between front and rear. Adjust if necessary.
3) Fit the end cross
members into place and pre-drill for 3” screws
4) Fit the center cross
members into place and pre-drill for 3” screws
5) Assemble the end
and center cross members with 3” screws
6) Flip the entire
frame over
7) Fit the gussets
to all corners and center cross member and pre-drill for 2” screws
8) Assemble the gussets
with 2” screws
9) Flip the entire
frame over again
Bunk Risers
Note: If your hull design requires any of the bunk
risers to have an angle cut complete these cuts before the final assembly of
the bunk risers onto the base frame if you have a table saw or compound miter
saw. If not then mount them first and cut the angle with a skil saw.
1) Assemble the 4
corner pieces with 2” screws only before mounting to the frame
2) Fit the corner
pieces into place with the 5” side facing to the short length of the frame
3) Pre-drill thru
the base frame into each of the riser members. Short and long length sides
4) Fit the center
risers to the center cross member and pre-drill thru the riser
5) Assemble all
risers to the base frame with 3” screws
Castors
1) Using a castor,
place on the inside the corner riser and mark all 4 mounting holes. Do this at
all 4 corners noting the direction of the long side of the castor base plate
2) Place a support
under the frame and drill holes with clearance drill size for a 3/8” bolt
3) Flip the frame
over and let it stand on the risers
4) Mount the 4
castors using the 3/8-16 hex hardware and flat washers
5) Tighten until set
into wood member
6) Flip the frame
back over to the upright side
Bunks
1) Set the 2 x 6
bunks onto risers
2) Align the bunk
flush with the outside base frame and end of base frame
3) Layout the risers
on top of the bunk to get a screw pattern
4) Pre-drill each of
the riser locations for 3” screws
5) Mount bunks with
3” screws
