LUSITANO RETREAT — P01 BUILD NOTES
Use only with the main pallet guide and material intake checks. Illustrative dimensions are not a structural rating.

MEASUREMENTS
1. Outside 300 × 200 mm; wall height 45 mm
2. Illustrative timber t = 15 mm; plywood base 6 mm

CUT LIST / COMPONENTS
1. 2 sides 300 × 45 × 15 mm
2. 2 ends 170 × 45 × 15 mm
3. 1 base 300 × 200 × 6 mm
4. Optional removable dividers: measure inside after assembly

TOOLS
1. Tape measure, pencil and square
2. Clamps and a suitable supported cutting bench
3. Saw appropriate to the material; follow its instructions
4. Drill, matched pilot/clearance bits and screwdriver
5. Metal detector, suitable dust extraction and task-appropriate PPE
6. Sanding block and abrasive; finish tools as specified

ASSEMBLY
1. Prepare a full-size layout for the small fixings tray using the dimensions below. Measure the actual reclaimed thickness, write the part numbers on a drawing and confirm that the example fits its intended position before selecting timber.
2. Accept only dry, known-history timber that passes the guide’s intake checks. Remove nails and staples, scan the planned cuts for hidden metal and reject oily, mouldy, rotten or badly split pieces before machining.
3. Mark both 300 mm sides and both 170 mm ends on sound timber. Keep cracks and old nail holes outside the proposed corner screw positions; write the part number on the inside face before cutting.
4. Dry-fit the ends between the sides on the 300 × 200 mm base. Clamp gently and compare the two diagonals; correct the joints until the box is square before making any fixing holes.
5. Mark corner screws centrally in the end-board thickness. Drill pilot and clearance holes to suit the chosen screws and timber, countersink only enough for a flush head, then assemble while the corners remain clamped.
6. Place the assembled walls on the base and trace their position. Fix the base into sound wall edges using screws selected for the actual thickness, checking that their tips cannot break into the tray.
7. Measure the finished interior rather than the original drawing. Cut loose dividers to fit with removal clearance, ease their edges and arrange compartments around the fixings actually used without forcing the walls apart.
8. Finish by checking every accessible face with a cloth to reveal snags, inspecting fasteners and comparing the assembly with the drawing. Record the timber batch, actual dimensions and inspection date before putting this project into its intended service.

FINISH AND CARE
1. Ease exposed edges and remove sanding dust before finishing. Follow the chosen product’s preparation, application, ventilation and curing instructions.
2. Keep the board batch and product record. Reinspect joints and surfaces after initial use and whenever exposure or contents change.

COMPLETION CHECKS
1. No loose splinters, protruding points, moving joints or trapped access. Confirm the stated use and supports match the completed assembly.
2. Illustrative dimensions describe reclaimed parts only; they do not establish a structural capacity, food suitability or approval for another use.

Guide: https://lusitanoretreat.com/build-guides/building-with-pallets/#project-p01