LUSITANO RETREAT — P09 BUILD NOTES
Use only with the main pallet guide and material intake checks. Illustrative dimensions are not a structural rating.

MEASUREMENTS
1. Example coupons 150 × 75 mm
2. Retain original thickness and identify every timber batch

CUT LIST / COMPONENTS
1. 6 or more coupons 150 × 75 mm
2. 1 untreated control per timber batch
3. Two matching sets for sheltered and exposed comparison

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 finish sample library 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. Choose representative accepted boards with different grain and weathering, and assign a batch code before cutting. Mark that code on the back of each 150 × 75 mm coupon so sanding cannot remove the identification.
4. Cut paired coupons from adjacent sound areas where possible. Ease the edges, remove dust using an appropriate method and prepare each face exactly as the finish manufacturer requires; retain an untreated control.
5. Label each sample with product, colour, preparation, number of coats and application date. Apply only the specified coverage and drying conditions, avoiding heavy artificial coats that would make the comparison unrepresentative of the eventual wall.
6. Keep one matching set sheltered and place the other in representative outdoor exposure on a suitable existing support. Keep labels readable and avoid puddles unless that exposure is actually part of the intended use.
7. Photograph both sets together at fixed intervals under similar light. Compare colour, checking, adhesion and water marks, record the observations and retain the selected coupon as a reference for later production batches.
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-p09