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DIY – Plyo Box (30″ x 24″ x 20″)

Another quarantined weekend means another DIY project. We decided we wanted to make some boxes for box jumps. After looking at several tutorials we choose the one I have included here. Since there are so many tutorials already, I decided not to redo what has already been done but plenty of more skilled people. So instead what I want to do is give you one tutorial we liked, and then explain what issues we ran into and overcame as novice woodworkers so that you can make a box yourself without running into the same issues.

The basic overview is you just need a few tools and 1 thick (approx. 3/4 inch) piece of 4′ x 8′ plywood and nails. You cut up the board to make 6 different sides to a box as well as 1 piece of wood that goes inside for support. You nail everything together and that’s it. With that said I will go over this in a little more details with emphasis on what we learned from the 1st box to the 3rd that made our process more efficient and clean.

This is a great video going over everything

Tools:

Even though you could possibly do with less fancy tools listed below, I personally think it is very difficult and time consuming to use a basic saw to cut long straight (as possible) lines or just a screwdriver to screw in relatively large amount of nails.

  • Circular Saw
  • Drill (with bits to screw in screws and I suggest drill bits to pre-drill the holes so that you don’t splinter the plywood)
  • Something straight to measure and draw straight lines
  • Pencil

 

 

 

Materials:

View Home Depot Shopping Cart
  • 3/4 inch 4′ x 8′ Plywood
  • 30-40 3″ screws

Directions:

  1. Since we found this a challenge, this step is just getting the plywood home. We had to tie it to the roof of our car because we couldn’t fit it inside. So be prepared to figure out how to get it home. One idea I had after the fact is if you look at the diagram of your cuts, you could ask someone at home depot to carefully cut the board in half along the long side. That would still give you everything you need to form the box and should be easier to fit in your car. HOWEVER, make sure you get a perfect cut down the middle else you could mess up your whole box.
  2. Once you have the box home, the mistake we made in the first attempt is to actually draw out ALL the lines shown in the diagram. The reason I don’t recommend doing this, is those lines assume that every cut you make will be perfect and for me that is not a high degree of certainty. In other words it’s better that you be prepared to make small mistakes but plan for it so you end up with a nice box that might be a tiny bit shorter (ie. 20 x 23.8 x 29.8) but identical on all matching sides, then risk one side being longer than the other and creating gaps.
  3. So here is what we did, draw the first line which is 30″ from the shorter side.
  4. Cut that off in as straight a line as possible.
  5. Measure the halfway point for that piece, draw the line and cut again.
  6. You should now have 2 identical pieces, but if you are like us, compare those 2 pieces and if there is slight differences, trim the wood a little so they match up correctly.
  7. Now repeat steps 3-6 for the 18.5″ cut from the remaining plywood.
  8. Now repeat steps 3-6 for the 28.5″ cut from the remaining plywood. Cut off the scrap parts.
  9. Finally set aside the last long piece which will be what you create the support from.
  10. Put the box sides together and see if all the cuts match well enough to begin screwing.
  11. We drilling in handles at this point so we could sand them on both sides before the box is build together.
  12. If they are all done well enough, you can screw together everything to form a square but do not close up the square. You will need to measure and cut out your support piece to fit it inside the box.
  13. Once you have the support fitting tightly inside, then screw the support to the box and finally seal it up and additional screw to tighten everything.
  14. You are done and have build yourself a beautiful box for box jumps.

Here is a timelapse of us making the boxes

Alex Bykov is a Web Developer by trade who has always looked for ways to combine his passions for CrossFit with his professional skills. Alex started CrossFit about 3 years ago to keep up with his kids and loved it so much he never looked back. In his nerdier days, A-Train also designed board games and card games for various companies. Check out his work at AlexByDesigns.