LUSITANO RETREAT — P11 BUILD NOTES
Use only with the main pallet guide and material intake checks. Illustrative dimensions are not a structural rating.

MEASUREMENTS
1. Example outside 300 × 220 mm; height 120 mm
2. Illustrative t = 15 mm; contents remain lightweight

CUT LIST / COMPONENTS
1. 2 sides 300 × 120 × 15 mm
2. 2 ends 190 × 120 × 15 mm
3. 1 known clean base 300 × 220 mm; measured thickness recorded

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 small decorative storage box 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 intended leaflets or labels in a 270 × 190 mm paper rectangle to check useful internal space. Adjust the plan for the actual contents and measured board thickness before cutting the illustrative 300 × 220 mm box.
4. Cut two 300 mm sides and two 190 mm ends, all 120 mm high for the example. Mark their inside faces and reject split corners rather than hiding damage beneath paint or a decorative trim.
5. Dry-fit the end pieces between the sides and clamp on a flat bench. Compare diagonals and mark screws centrally in the sound end-board thickness, clear of old nail holes and weakened edges.
6. Pilot and fasten the corners, then trace the assembled walls onto the base. Attach the base with suitable short screws, checking that every point remains within the intended wood and cannot snag the stored paper.
7. Ease the entire rim and corners, apply the intended indoor finish and allow it to cure. Put the box on a stable shelf, label its contents and move it empty because the sides are not designed 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-p11