Jan 18 , 2019
Time, money and tools
Building this set will take you two or three days, plus a few hours of finishing work. These pieces were built from cherry boards and cherry plywood. Cherry is expensive—made from oak, maple or birch this project will cost much less. For a more rustic look, use pine and plywood and spend even less.
This project requires two special tools: a table saw to rip solid wood to width and a pocket screw jig to make strong butt joints. If you don’t own a pocket screw jig, buy one. It’s a good investment and is easy to use. In addition, you’ll need a drill, miter saw, random orbital sander and jigsaw. An air-powered 2-in. brad nailer isn’t absolutely necessary, but it’ll save lots of time and give you better results.
Cut parts to size
Rip the parts for the grille. Cut all the slats to identical lengths using a bump jig. Make fine length adjustments by turning the lag screw in or out.