LUSITANO RETREAT — P27 BUILD NOTES
Use only with the main pallet guide and material intake checks. Illustrative dimensions are not a structural rating.

MEASUREMENTS
1. Example external surround 300 × 200 mm; actual removable tray determines the final fit.
2. Example 15 mm rails, 35 mm high; provide a small clearance so the tray lifts out freely.

CUT LIST / COMPONENTS
1. Long rails: 2 × 300 × 35 × 15 mm.
2. End rails: 2 × 170 × 35 × 15 mm for the example outside width.
3. Two removable resting strips sized to the actual tray; keep coating-contact parts compatible with that coating.

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. Read the actual coating instructions and choose a removable tray suitable for its residues. This rest holds clean or drying brushes; it is not a solvent bath, wash station or container for contaminated rags or uncontrolled liquid waste.
2. Measure the tray including flanges and handles, then draw a low surround that permits vertical removal. Use the 300 × 200 mm example only if the tray fits with cleaning clearance; identify where the brush heads and handles will rest.
3. Select accepted small rails, remove damaged ends and scan for metal before cutting. Measure thickness t and calculate ends from the chosen outside width minus twice t; keep the surround height below the tray features needed for lifting.
4. Cut paired long rails and paired ends, then dry-fit on a flat bench with the empty tray in place. Check diagonals and mark corners; take the tray out before drilling so it cannot be punctured by a pilot bit or screw.
5. Clamp and pre-drill each corner for the selected suitable new screws. Assemble the low frame with tips contained within the timber, then return the empty tray and confirm that no fixing presses against its wall or bottom.
6. Position removable resting strips across the compatible tray so brushes remain separated and stable. Choose the strip material for the coating and cleaning method; trim to the measured tray geometry and keep the tray removable without dismantling the timber surround.
7. Round handle-contact edges, vacuum dust and apply only a finish suitable for the intended workshop area. Let it cure, then test the dry arrangement with clean brushes; adjust strip positions so handles do not roll into neighbouring tools.
8. Place the rest on the finishing bench away from ignition sources as required by the coating instructions. Remove the catch tray for correct cleaning and waste handling after each job; do not allow liquid residues to soak into reclaimed timber.

FINISH AND CARE
1. Smooth dry timber surrounds the separate compatible tray.
2. No solvent soaking or torch finishing; coating instructions govern residue management.

COMPLETION CHECKS
1. Tray lifts out, handles are stable and no screw touches the tray.
2. No stored rags or accumulated coating residue; inspect before reuse.

Guide: https://lusitanoretreat.com/build-guides/building-with-pallets/#project-p27