LUSITANO RETREAT — P25 BUILD NOTES
Use only with the main pallet guide and material intake checks. Illustrative dimensions are not a structural rating.

MEASUREMENTS
1. Example outside footprint 340 × 220 mm; base thickness 6 mm.
2. Example rails are 15 mm thick; rear 170 mm high, front and ends 70 mm high.

CUT LIST / COMPONENTS
1. Base: 1 × 340 × 220 × 6 mm known suitable panel.
2. Long front: 1 × 340 × 70 × 15 mm; long back: 1 × 340 × 170 × 15 mm, or separate accepted slats on a clean backing.
3. Ends between long faces: 2 × 190 × 70 × 15 mm. Optional loose card dividers fit the measured interior.

TOOLS
1. Tape, pencil and square; clamps and a flat bench.
2. Suitable saw, drill/driver and pilot bits matched to the chosen fasteners.
3. Sander with effective extraction; metal detector before machining accepted boards.

ASSEMBLY
1. Measure the tallest and widest leaflet actually used by guests. Mock up a 340 × 220 mm footprint in cardboard and check that the low front reveals titles while a hand can remove one guide without bending it.
2. Select dry, accepted boards for the front and ends and a known clean base. Mark knots, splits and former fastener holes; move each cut line into sound wood and scan the full cutting area before using tools.
3. Measure actual rail thickness t and calculate the end length as 220 minus twice t. Mark matching ends together, then cut the base, front, rear and ends; check each piece against the drawing rather than measuring from another offcut.
4. Prepare a flat bench and dry-fit the ends between the full-width front and back. Place the base underneath, compare diagonals and check that the leaflet stack fits; label the four corners to preserve the successful arrangement.
5. Clamp one corner at a time and mark pilot holes through the long face into the end piece, clear of old holes and split edges. Select screws for the actual timber and joint; drill and assemble without crushing thin material.
6. Turn the frame upside down and centre the base over its edges. Mark fixing lines over timber rather than the open interior; pre-drill and attach with screws whose engagement and tip position remain inside the assembled object.
7. Cut loose card dividers to the measured interior and keep them below the leaflet headings. Round the rim and remove dust with extraction; apply the chosen indoor finish and allow its full cure before replacing any paper.
8. Place the empty holder on the intended stable reception surface and check for rocking. Add current guides gradually, confirm unobstructed removal and label a review date; keep required emergency information visible in its own permanent location.

FINISH AND CARE
1. Ease all paper-contact edges; no rough internal screws.
2. Indoor finish only as labelled; cure before paper or guest contact.

COMPLETION CHECKS
1. No rocking or loose base; cloth and paper do not snag.
2. Guides remain readable, dry and removable; holder is not a carrying crate.

Guide: https://lusitanoretreat.com/build-guides/building-with-pallets/#project-p25