LUSITANO RETREAT — P04 BUILD NOTES
Use only with the main pallet guide and material intake checks. Illustrative dimensions are not a structural rating.

MEASUREMENTS
1. For tray outside width W and depth D
2. Illustrative removal clearance 5 mm each side; rail height 30 mm

CUT LIST / COMPONENTS
1. 2 long rails: W + 10 + 2t mm
2. 2 end rails: D + 10 mm
3. All rails 30 mm high; t is actual rail thickness
4. No wooden base: commercial tray contains water

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 boot tray surround 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 commercial tray at its widest outside rim, not just its base. Set out W + 10 mm by D + 10 mm clear space and confirm that the tray can lift vertically without flexing the timber.
4. Cut two long rails to W + 10 + 2t and two ends to D + 10 mm. Mark the end rails between the long rails; keep the surround low and round the exposed outside corners.
5. Dry-fit around the empty tray on a flat surface, then remove the tray before drilling. Clamp and pilot the corner joints, using screw lengths that remain inside the timber and cannot puncture the tray.
6. Ease a shallow finger recess in an accessible rail if needed, keeping adequate timber around the joint. Test lifting with wet-weather gloves before applying the finish, rather than adding a projecting handle beside the door.
7. Finish all faces and end grain, allow the stated curing time and replace the tray. Position outside the walking line, check the door fully opens and empty collected water before it overflows onto the wood.
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-p04