Waltons Saw Mill

High-quality product, on time and within budget.

by Leslie Garisto Pfaff

As soon as she could navigate the backyard under her own steam, my daughter, Lily, began staking her claim to ever-increasing pieces of property. Under a canopy of vines, she and her friends forged alliances, rewrote the rules of civilized behavior and generally had a heck of a good time. But then came the day when Lily and her friends needed shelter from the elements; they needed four walls and a roof over their heads; they needed . . . a playhouse.

We settled on lattice as the main building element and colorful canvas for the roof. To make our job even simpler, we opted for highly durable plastic lattice, which can be cut with a circular saw, requires no painting and virtually no maintenance, and is splinter-free. The lattice would enable Lily and her friends to attach a variety of neat "extras" to the playhouse using nothing more complicated than a series of S-hooks.

We were able to build the entire playhouse in under ten hours. And even using durable pressure-treated lumber, we still kept our costs under $300. Here are a few tips we learned while building:
• Grade the site before beginning construction.
• Using screws and a variable-speed drill, instead of nails and a hammer, makes construction easier.

Backyard Playhouse: Materials List
We used pressure-treated lumber to keep costs down.However, you may decide to choose a naturally weather-resistant wood, such as cedar, which, although more expensive, is just as durable but not as hazardous as treated lumber. When working with pressure-treated lumber, be sure to always wear eye protection and a respirator when sawing wood. Dispose of all sawdust and scrap pieces properly (never burn treated wood) and wash clothes separately from other laundry.

MATERIALS
Two 4" by 4" by 10' boards, each cut into two 60" pieces; label each A
Two 4" by 4" by 8' boards, each cut to 84"; label each B
Four 2" by 4" by 12' boards, each cut into one 82 1/2" piece; label two C and two D; and then into one 55" piece--F
One 2" by 4" by 12' board cut into one 82 1/2" piece; label D; and one 43" piece; label E
One 2" by 4" by 8' board cut into two 45" pieces; label G
Two 2" by 2" by 8' boards, each cut to 55"; label each Or, if 2 by 2's are not available:
One 1" by 3" by 10' board cut into two 55" pieces--H
One 1" by 3" by 8' board cut into two 48" pieces--J
Five 8' long lattice channels, each cut into two 48" pieces
Three 4' by 8' plastic lattice panels cut to fit openings between posts (you'll need 3 pieces approximately 36" by 48" and 2 pieces approximately 45" by 48")
One 48"-wide by 10'-long sheet of canvas (or any outdoor water-resistant fabric)
2 lbs. 12d galvanized common nails
1 lb. 6d galvanized box nails
1 lb. 2 1/2" galvanized screws (optional)

Approximate cost of materials:
Pressure-treated: $250
Cedar: $340

TOOLS
tape measure
circular saw
hammer
rubber mallet
nail set
cordless screwdriver or variable speed drill (optional)

Front and Back Wall

STEP 1:
Begin front wall assembly by nailing plate board (C) to the bottom of corner posts (A). Place center post (B) in the middle of plate board (C) and nail through (C) into the bottom of (B). Repeat Step 1 to build back wall assembly.
NOTE: Unless specified, all nails are 12d. Or you can substitute screws for nails.

STEP 2:
For back wall, nail bottom rail (D) to corner posts (A) and center post (B), flush with edge of bottom plate (C). Nail top rail (D) to corner posts (A) and center post (B), placing it 4 inches from top of corner posts (A).

STEP 2A:
For front wall, nail bottom rail (E) to corner post (A) and center post (B), flush with bottom plate (C). Nail top rail D to corner posts A and center post B.

Side Rails
STEP 3:
Nail bottom side rail (F) to plate board (G), forming an upside-down "L" and leaving a 5-inch space at each end. Repeat for other side.

STEP 4:
Flip over the back wall so that top and bottom rails (D) are facing down. Nail top side rail (F) to corner post (A) where top rail (D) intersects. Nail bottom side rail assembly (F) and (G) to corner post (A) where bottom rail (D) intersects.

Attaching Walls

STEP 5:
Tilt up back wall soside rails (F) are horizontal. Attach front wall assembly by nailing through side rails into corner posts (A).

STEP 6:
Use 6d galvanized box nails to attach lattice channels to the inside of the corner posts (A). Use a nail set to drive nail heads flush with inside track of channel.

Attaching Lattice and Canvas

STEP 7:
Measure openingsbetween posts and cut lattice panels to fit. Slide lattice panels into channels between posts. (You may want to spray a lubricant, such as silicone, to ease the process.) When panel is as low as it will go, tap it with a rubber mallet for a secure fit.

STEP 8:
Nail ridge poles (H) to sides of center posts (B). (The poles will extend 1 1/2 inches on each end.)

STEP 9:
Drape canvas over top of ridge poles and fasten to side strips (J) by wrapping canvas around the strips and then nailing them to the top side rails (F) with 6d box nails (or use screws for easy removal for cleaning, etc.).

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