LUSITANO RETREAT — P03 BUILD NOTES
Use only with the main pallet guide and material intake checks. Illustrative dimensions are not a structural rating.

MEASUREMENTS
1. Example outside footprint 400 × 300 mm
2. Wall height 150 mm; illustrative t = 15 mm

CUT LIST / COMPONENTS
1. 2 sides 400 × 150 × 15 mm
2. 2 ends 270 × 150 × 15 mm
3. 1 known sound base 400 × 300 mm; thickness selected for contents

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 low offcut sorting boxes 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. Measure the clear space beneath the bench and mark a 400 × 300 mm footprint on the floor. Check that the planned 150 mm sides and contained offcuts remain clear of knees, doors and the walking route.
4. Cut the two long sides and two ends, keeping the 270 mm ends between the long sides. Arrange the soundest board faces inside and reject any corner that cannot accept a fixing away from a split.
5. Dry-fit and clamp the four sides on a flat surface. Check matching diagonals, drill pilots for the selected new screws and fasten each corner without drawing a twisted board forcibly into position.
6. Trace the assembled walls onto the base and attach it with screw lengths matched to the measured materials. Check the underside and interior for exposed tips before putting the box directly on the floor.
7. Divide contents by usable length and label the end facing the workshop. Add only short contained offcuts, remove projecting pieces and move the box empty; decorative sides are not carrying handles.
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-p03