Materials: 2 4'x8' sheets of 1/2" plywood
1 4'x8' sheet colored PVC (1/4")
1 4'x4' sheet colored PVC (1/4") - different color
1 1/2" aluminum tube (approx. 12 feet)
2 6' all thread (1/2" diameter)
pre-fabricated 1/8" aluminum sheeting for walls
1 4'x8' sheet of 2" foam insulation
contact adhesive w/ caulk gun
circular saw
chop saw
rotary cut off tool
electric drill w/bits
jigsaw
scouring Pads
dog beds
Bauhaus Doghouse Construction
1. To get started have your local aluminum manufacturer do the break work (the bending of the aluminum sheeting to your specifications). You will need one channel pan in 16 gauge aluminum 71"x26" with 2" flanges turned in (figure A). The sidewalls need to be angled from 21" high at the front to 14" high at the rear. You will then need three channel pans 24" deep by 21" wide with 2" flanges turned out. The sidewalls on all three of these needs to be the same as the large channel pan.
2. Using 1/2" thick 4'x8' sheets of plywood (figure B), cut out the roof at 77"x36", and the floor at 77"x30". Then using 1/4" PVC colored plastic sheets, cut out the roof at 79"x38" and the floor at 79"x32".
3. To adhere the PVC sheet to the wood for both the roof and the floor, use contact adhesive (figure C). Cover one side of the plywood for the roof, and one side of plywood for the floor and attach the PVC to the plywood leaving a 1" overhang in the front and back.
4. Using another piece of PVC, cut out a piece at 71"x21" to be used as the front of the house. Once it is cut to size, use a jigsaw and trim out the doors. The size of the doors is predicated by the size of the dogs using the house. If you have small dogs, the door should be short and wide to fit the dog and if you have taller ones the door will need to be taller and narrower. The final size is a matter of personal judgment.
5. Now, onto the columns (figure D). Using 1-1/2" aluminum tubing, cut four pieces, on a chop saw, at 23" long for the front, and 4 at 12-1/2" long for the back. Then, cut out the all-thread using a cut off tool. For these you will need four at 26" long, and 4 at 15-1/2" long.
6. Insulating the doghouse will require one sheet of 2" foam (figure E). The sheets come in 4'x8' sheets. Cut 2" foam insulation to fit in between all walls between each of the three channel pans, as well as in the back. To cut the insulation, use the blade from a hacksaw or a sharp razor knife (figure F).
7. Once the walls are insulated, use 1" angled aluminum to attach the exterior aluminum wall panel to the floor. Cut the angled aluminum to 26" long using a standard chop saw. Align the angled aluminum along the sidewall and floor and pre-drill three holes on the lower and upper sides of the aluminum (figure G). Use wood screws to attach the aluminum to the floor and metal screws to attach it to the sidewalls. Do this on both sides of the doghouse.
8. Mark and drill holes for columns. To find the locations for the columns, measure out 2-1/4" from the bottom corner of the house on both axes and then connect the lines to find the placement for the columns in the corners of the doghouse. Once you've marked the floor, transcribe that mark to the roof using a straight edge. Repeat this for the four corners.
9. To assemble the columns, put a nut and 2" washer on one end of the all-thread and then place the cut piece of aluminum tubing between the floor and roof (figure H). Slide the all-thread down from the roof through the tubing and out the hole in the bottom of the floor. The nut and washer at the top of the all-thread will hold the assembly from the top (figure I) while another nut and washer need to be applied to the bottom of the all-thread that protrudes from the bottom of the floor. Any excess all-thread should be removed from the bottom of the house using a cut off tool (figure J).
10. The front wall of the doghouse that is made from the PVC sheet is now bolted onto the assembled and insulated break work. Pre-drill holes into the front wall that will match up to the flanges on the break work and then use 1/4-20 nuts and bolts to attach the front sheet to the flanges on the front of the house. The heads of the bolts will show on the front of the house, so creating a nice even pattern when placing the nuts and bolts is suggested (figure K).
11. The last step is to use abrasive pads on the exposed aluminum of the doghouse (figure L). That includes the side and back walls and aluminum columns. Firmly rub the surface of each piece of aluminum with the abrasive pad to give the whole house an even finish.
12. The doghouse looks great for dachshunds, or any other type dog (figure M)!