LUSITANO RETREAT — P02 BUILD NOTES
Use only with the main pallet guide and material intake checks. Illustrative dimensions are not a structural rating.

MEASUREMENTS
1. Example facing panel 600 × 450 mm
2. Backing and wall mounting specified for actual tools

CUT LIST / COMPONENTS
1. Illustrative face: 6 slats 600 × 70 mm with 6 mm gaps
2. Backing size and thickness selected for hooks and mounting
3. Hook count and positions from full-size paper tool layout

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 light tool shadow board 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. Trace each intended light tool on a 600 × 450 mm paper layout. Leave enough space above each outline to lift the tool off its hook, and mark the sharp ends that need covers.
4. Lay six prepared slats across the backing with temporary 6 mm spacer strips. Mark the backing fixing positions and hook locations so hooks enter sound timber and their intended backing, never an open gap.
5. Clamp the slats to the backing on a bench. Drill and fasten using lengths suited to the actual combined thickness; remove temporary spacers, turn the panel over and check for protruding screw tips.
6. Transfer the tool outlines with contrasting paint or labels after the finish cures. Fit each hook using its intended mounting arrangement and check that the tool can be lifted and returned without catching adjacent hooks.
7. Identify the wall, concealed services and complete loaded weight before selecting mounts. Install only with the mounting arrangement checked for that wall, then add tools individually while checking retention and accessibility.
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-p02