This is a simple project
that should only take a couple of hours to complete.
Supplies:
You will need
2 - 12' 2x4's (uprights)
2 - 8' 2x3's (rungs)
Exterior wood glue
36 - 2-1/2" Deck Screws
Tools:
4 Clamps
Measuring Tape
Square
Pencil
Circular Saw
Drill with countersink and screw bit
Hammer
Chisel
Start by clamping the two 12' - 2x4's together with
the top edge and ends flush. Stand them on edge. The
rungs are notched into the 2x4 upright 1-1/8" so
we need to mark out notches. The top and bottom rungs
are 8" from the ends, place a mark at 8". This
is the top of the upper rung and the bottom of the lower
one. Offset these marks 2-1/2" (the width of the
2x3 rungs).
Now measure out for the rest of the rungs. Lay your
tape measure on the 8" mark made earlier and measure
16" increments. These marks represent the center
of the intermediate rungs. Offset these marks 1-1/4" on
either side.
Using your square, square off the marks you have just
made down the face of the 2x4 uprights 1-1/8" deep.
Square your marks across the top edge of the uprights
as well.
Now it is time to cut the notches. Set the depth of
your circular saw to 1-1/8". Start by making the
cheek cuts of the notch then proceed to make a series
of cuts about a 1/4" apart through the rest of the
notch. Do this for all the notches.
Before removing the clamps use your hammer to break
out the wood in the notches and clean up each notch with
your chisel.
Unclamp the two uprights and set them aside. Now cut
all the 2x3's into 19" lengths. You will get 5 out
of each 2x3 but since we will only need 9 rungs you will
have 1 extra. Each rung is attached to the upright with
exterior wood glue and deck screws. You will need to
drill two countersinks on each end of the rung (so 4
per rung).
Now attach them to the uprights starting with the top
and bottom rung. You might need to use your hammer to "convince" the
rungs into the notch. Don't force them into the notch
if it too tight. They should only need to be tapped in
not beat to pieces.
Put some of the exterior wood glue into both notches
and insert a rung. Make sure the rung in flush to the
outside of the uprights. Secure in place with 4 deck
screws (2 on each end). Continue this for the reminder
of the rungs.
Protect you ladder with a durable finish like paint
or stain.
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