LUSITANO RETREAT — P08 BUILD NOTES
Use only with the main pallet guide and material intake checks. Illustrative dimensions are not a structural rating.

MEASUREMENTS
1. Example backing face 400 × 300 mm
2. Brush and removable tray sizes measured before cutting

CUT LIST / COMPONENTS
1. Example face: 4 slats 400 × 70 mm with 6 mm gaps
2. Backing/support and fixings selected for brushing forces
3. Replaceable purpose-made brush and separate catch tray

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 hand-tool cleaning station 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. Place the brush and catch tray on paper and mark their actual fixing points. Arrange a small hand tool beside them with enough hand clearance to brush away from the body without meeting another sharp edge.
4. Prepare four illustrative 400 × 70 mm facing slats and dry-fit them with 6 mm gaps. Position brush fixing points over sound supported material, not a gap or an old nail hole concealed beneath the brush.
5. Fix the facing to its suitable backing or bench support using the reviewed connection arrangement. Keep the catch tray removable and do not screw through its water- or soil-containing surface to mount the station.
6. Attach the replaceable brush only through its intended mounting points, and fit a cloth hook clear of the working stroke. Check that the brush cannot rotate or expose fastener tips where hands pass.
7. Try the station with one small manual tool, brushing towards the catch tray while keeping fingers behind the cutting edge. Remove and empty the tray, inspect the connections and adjust access before regular use.
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-p08