Crates #1: Aircraft Carrier Steam Catapult Launching Engine Cylinder Cover Shipping Skids.

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Blog entry by PASs posted 03-06-2013 06:34 AM 3358 reads 0 times favorited 2 comments Add to Favorites Watch
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This covers the construction of 26 shipping skids described in project 80698.

86 – 4×6s 16 feet long
26 – 2×6s 8 feet long
234 – 1/2×10 inch galvanized hex head bolts
234 – 1/2 inch galvanized nuts
468 – 1/2 inch galvanized washers
780 – 3 1/2 inch framing nails

Hitachi 12 inch miter saw
DeWalt miter saw stand.
Black and Decker 1/2 inch “Hole Hog” drill, all metal construction
Porter Cable Framing Nailer
Campbell Hausfeld 1/2 inch impact gun
Framing Square
8 – 12 inch Bar clamps

Miter saw extension support (made on site)
Spacing and alignment jig (for one end)
Spacing jig for other end
Storyboard for marking stringer position.

First skid – 3 1/2 hours due to jig up and assembly sequence mistake.
Last skid ~30 minutes.

Cutting and drilling is done with the skids upside down due to requirement to recess the hex bolts.
1. Move 3 4×6s 16 feet long onto the work table.

2. Move them one at a time to the miter saw and cut to 148 inches for top deckboard/runners.

3. Move the 148 inch piece back to the work table and cut the left over piece to 42 1/2 inches for stringers.
4. Put alignment jig on one end. The jig sets the spacing of the deckboards, aligns the ends, and sets the location of the end stringer.

5. Make bolt hole locations on stringers with storyboard.

6. Drill recesses for hex bolt heads. Using 1 1/2 inch forstner bit with shop-made depth gauge.
7. Move stingers to deckboards and clamp in position. End opposite the alignment jig is storyboarded for positioning and jigged for spread.
8. Auger 5/8 holes through stringers and deckboards

to remember to keep the pieces in the same relative locations when moving them to the assembly area as the holes are free-hand drilled.
9. Remove clamps and jigs and move pieces to assembly area. Stringers are flipped end for end to put the recess holes on the bottom. Deckboards are turned over and placed on top of stringers.
10. Reattach alignment jig, quick fit bolts, clamp deckboards to jig.
11. Tighten deckboards.
12. Nail end braces to deckboards.

It would be easier If I could do all the assembly on the worktable, but pictures will show the placement of the other equipment prevents a forklift from getting in.

Total time for all the above averaged 30 minutes each …with 20 at the quickest (bolts went through quicker.)

Drilling the bolt head recesses in the bottom of the stringers.

Augering the bolt holes… 5/8 inch holes for 1/2 inch bolts….easier to reassemble

-- Pete, "It isn't broken, you just aren't using it right."

2 comments so far

View stefang's profile


16074 posts in 3512 days

#1 posted 03-06-2013 10:26 AM

This should be worth waiting for.

-- Mike, an American living in Norway.

View Roger's profile


20949 posts in 2982 days

#2 posted 03-06-2013 01:34 PM

Oh how I’d like to have a big ole catapolt on the top o my hill. I could wipe out a whole herd o zombies. :)

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed.

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