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How to make a Kicker Ledge
This Kicker Ledge or funbox, is super simple and if you've built the kicker from this site, you're half way done.
The kicker is 6' long, 4' wide and 1'-6 tall. The box is 4' long, 7' wide and 1'-6 tall. This set of plans shows the kicker and box attached by bolts, but is not necessary.
How to make an Kicker Ledge - Preparation
The plywood, lumber and screws can be found at most home improvement stores. However, the steel angle iron and threshold can be a little more tricky to obtain.
First try "Steel Yards", "Steel Fabricators" or "Structural Steel" in the phone book. If these aren't available, try a home improvement store, such as Menards, Home Depot or Lowes. Finally, if you're still having difficulty, try "Scrap Yards", "Junk Yards" or "Salvage Yards" in the phone book or online.
If you plan on leaving this structure outside, you will want to use pressure treated wood, water sealant or paint and a tarp.
Build it
Gather your materials. This set of plans is exactly like the kicker plans with the addition of a 4'-0 wide × 7'-0 long × 1'-6 tall ledge.
Start with the 2×4's for the kicker. Cut 10 pieces at 3'-10 1/2 in length (you will get 2 out of each 8' long 2×4). Set them aside.
Plywood cut list
Cut the plywood for the ledge and kicker by following the cut list below. This cutting diagram will allow you to use the 4 sheets of 3/4" plywood more efficiently.
Framing the bottom
Attach the previously cut bottom 2×4 cross members as shown.
Framing the top
Now attach the eight top 2×4 cross members, 8 inches on center starting from the bottom.
Don't cover the kicker in plywood just yet, you'll need the access to bolt the ledge to the kicker.
Building the ledge
Start with the 2×4's. Cut 14 pieces 3'-7 1/2 in length. Set them aside. Cut 6 pieces at 1'-6. These determine the height of the ledge. Finally, cut 4 at 6'-10 1/2 in length.
Using two of the 6'-10 1/2 long 2×4's and three of 3'-7 1/2 long 2×4's frame the bottom of the ledge to look like this. The one in the middle is centered.
It's a good idea to pre-drill the screw locations with a 3/16" drill bit to keep the wood from splitting.
Framing the top
Frame the top to look like this. Using two of the 6'-10 1/2 long 2×4's for the sides and eleven 3'-7 1/2 long 2×4's placed every 8" on center except where noted.
Attaching the sides
Attach the 6 pieces that are 1'-6 in length to the bottom of the box like shown here. Put four screws in each piece, 2 through each side or cross member.
Attaching the top
Place the top on the newly attached sides. This is easier if you flip the bottom over or lay it on its side. Put 4 screws in each just like the bottom.
Make sure the box is level and square. This is done by measuring diagonally from one corner to it's opposing corner and making sure this distance is the same as the distance from the other two corners.
Attaching the plywood sides
Your done framing the box. Now you want to attach the plywood as shown in the picture. Cut the two short sides at 3'-10 1/2 × 1'-6. Cut the two long sides at 7'-0 × 1'-6.
It is not necessary to cover the entire box in plywood, I do this for extra strength and it saves the supporting 2×4's from getting blasted every time someone loses a deck.
Bolting the ledge to the kicker
Now that the framing is done, center the kicker behind the ledge and drill two 9/16" holes about 6" in from the sides of the kicker.
You will want to go through both the ledges 2×4 and plywood and the kickers 2×4. That's 3 3/4" worth of wood to drill through so make sure your drill is strong and your drill bit is sharp.
Once the holes are drilled, bolt the ledges together using two, 1/2" x 5" bolts, nuts and washers.
Attaching the plywood
Cover the framed ledge with a piece of 3/4" thick plywood that is 4' wide by 7'-0 long.
Cover the framed kicker with a piece of 3/4" thick plywood that is 4' wide by 6'-2 long. The plywood should just touch the ground and meet the plywood of the ledge.
Attaching the masonite
Cover the ledge with a sheet of 1/4" masonite that is 4' wide by 7'-0 long.
Then cover the kicker with the 1/4" masonite that is 4' wide by 5'-8 long making sure the ledge masonite and the kickers masonite meets flush. Also make sure you hit the studs when you are placing the screws in the masonite. A good way to do this, is by laying out a chalk line.
Attaching the steel
If constructed properly, you should have about 1'-0 between the kickers masonite and the ground. This is where you place the 4' x 1', 3/16" thick sheet metal or 1/4" plastic.
Drill a 3/16" hole about 2 inches in from each side and one in the middle. After the holes are drilled, countersink each by using the 3/8" drill bit to drill down just enough so the screw heads are flush.
The steel threshold is also availabe at steel fabrication shops. You may be able to find the steel at home improvement stores too. They don't have the best selection, but it might be enough to get you by.
Attaching the coping
Cut your 8'-0 long angle iron in half. Place it on the edge and drill a 3/16" hole on each end on both sides where shown. The top and bottom dimensions are offset so the screws won't hit each other. Use about 3 screws per leg, 6 screws total per piece of angle iron.
After the holes are drilled, countersink each by using the 3/8" drill bit to drill down just enough so the screw heads are flush with the coping. This will keep your trucks and board from hitting them when you grind or slide.
Skate it
You are done my friend, slap a DIYskate sticker on that beast and have fun!
If you catch a mistake or feel something needs further explanation, please let me know.
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