LUSITANO RETREAT — P05 BUILD NOTES
Use only with the main pallet guide and material intake checks. Illustrative dimensions are not a structural rating.

MEASUREMENTS
1. Illustrative rectangular face 500 × 120 mm
2. Letter size chosen by actual approach-distance reading test

CUT LIST / COMPONENTS
1. 1 sound board 500 × 120 mm; actual thickness recorded
2. Paper lettering template and painted arrow
3. Mount spacing follows assessed existing support

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 retreat direction sign 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. Walk the route and write the destination and arrow direction on paper. Hold the template in the proposed position and check it from each approach, including the return route, before transferring anything to timber.
4. Mark a 500 × 120 mm rectangular panel on a sound board. Cut square ends, ease all edges and remove weak fibres; do not cut a narrow pointed arrow that creates a fragile sharp end.
5. Prime or prepare every face as the selected exterior finish requires. Paint a high-contrast destination and arrow from the template, leaving clear margins, and allow each coat to dry before masking or handling.
6. Hold the finished sign at its intended height and photograph it from the normal decision point. Enlarge lettering or shorten the wording if it is not readable before visitors reach the turning.
7. Mark fixing holes to match the existing suitable support and allow the mounting arrangement to address wind exposure. Pre-drill the panel, fit the selected fixings and walk the complete route again to verify meaning.
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-p05