LUSITANO RETREAT — P16 BUILD NOTES
Use only with the main pallet guide and material intake checks. Illustrative dimensions are not a structural rating.

MEASUREMENTS
1. Measure the existing bench front between legs; record clamp reach, knees and services.
2. Illustrative removable facing module: 400 × 300 mm, adjusted to the actual opening.

CUT LIST / COMPONENTS
1. Facing slats cut to the measured module width.
2. Two rear cleats cut to fit within the removable module.
3. Selected screw-fixed removable attachment or compatible panel fittings, fitted to sound bench members.

TOOLS
1. Tape measure, pencil and square; clamps and a stable cutting support
2. Metal detector, suitable saw and drill with timber bits; dust extraction and PPE appropriate to the operation
3. Sanding block, straightedge and the selected connection manufacturer’s installation tools

ASSEMBLY
1. Inspect the existing workbench independently and identify its load-carrying members. Sketch the front with leg positions, drawers, sockets, extraction hoses and the zones used by clamps and seated knees.
2. Divide the facing into small removable modules rather than one uninterrupted cover. Set each module’s finished dimensions from the actual clear opening, leaving its removal direction and hand access unobstructed.
3. Lay accepted slats on the bench and mark the module outline. Cut matching ends, ease corners and label the slats so the chosen arrangement can be reassembled after finishing.
4. Position two rear cleats across sound areas of the slats, clear of old nail holes. Select screws for the actual cleat-plus-slat thickness and pre-drill so no tip can reach the visible front.
5. Clamp the module square and fasten slats to the cleats, checking alignment after the first and last pieces. Keep any intended ventilation slots open rather than filling them with decorative offcuts.
6. Hold the module against sound bench members and mark the selected removable attachment points. Use accessible screw-fixed tabs or compatible panel fittings that can be released without dismantling the workbench.
7. Install one module and test normal bench operations before making the remainder. Open drawers, place clamps and reach services; trim or relocate the facing if it restricts the existing bench’s safe use.
8. Fit the remaining modules and label their concealed positions. Photograph the unobstructed services with panels removed, then record the removal tool and inspection interval beside the workshop maintenance notes.

FINISH AND CARE
1. Sand hand-contact surfaces and ease exposed edges; retain readable batch identification on a concealed face.
2. Use a finish selected for the actual exposure, following its preparation, coat and cure instructions; treat cut ends as specified.

COMPLETION CHECKS
1. Facing carries no worktop or tool load and does not cover vents or machine guards.
2. Every module can be removed without touching electrical connections.

Guide: https://lusitanoretreat.com/build-guides/building-with-pallets/#project-p16