By John RihaMore in Outdoors
Cut all box parts from the plywood. Clamp the work piece firmly to your sawhorses before making any cuts. Use a sharp cross-cut blade to reduce chips and splintering. Work slowly and let the saw do the work to ensure straight, splinter-free cuts. It won’t matter if you decide to cut directly on the lines you’ve drawn, or on the inside or outside edge of each line. However, once you decide how you’ll make your cuts, be consistent to ensure that all the pieces fit together properly.
When cutting the roof panels, cut one long edge of each roof panel with the saw blade set at a 45-degree angle. This bevel cut will ensure a tight-fight at the roof peak. Set the shoe of your circular saw at 45-degrees, and always unplug the saw before making any adjustments. When cutting, make sure to watch the blade as you follow your cut line. Don’t rely on the cutting guide on the shoe of the saw or your cut will be off. After you finish this bevel cut, one side of each roof panel will be slightly wider than the other. The wider surface should be the 20-inch dimension as indicated on the diagram, and is the upper side of each roof panel—forming the point of the 45-degree roof peak. Return your saw blade to the 90-degree position before cutting each roof panel to length.
Use a jig saw with a plywood-cutting blade to cut out the doorway. First, drill a 3/8-inch diameter starter hole for the jig saw blade at each bottom corner of the entry hole. Follow the lines carefully, and support the cutout piece as you finish the cut to prevent tear-out.
If your doghouse lacks adequate ventilation, the air may become hot and stifling during the summer, creating an uncomfortable environment for your pet. A few holes in the back panel near the peak will provide good cross ventilation. Drill three evenly-spaced holes with a 1 3/8-inch spade bit with spur cutters. Place a piece of scrap lumber directly under the hole locations to help reduce tear-out when you’re drilling through the plywood.
When you’re finished cutting out the pieces, sand all the edges with an orbital sander or sanding block and medium-grit sandpaper to remove any rough spots and splinters.