Monday, April 27, 2009

Mini Ramp in the Barn, Day One

So on Saturday morning I got up early, worked on my loose construction plans and headed to the local timber yard to make some purchases. I bought 10 sheets of 8' x 4' plywood. Unfortunately they didn't have the plywood in the thickness recommended by the the Dahlen/Pukeboy manifesto, so I had to settle for sheets that were in-between. The guy in the store assured me that, when soaked, the thickness I got was bendable. I was too excited about the prospect of my very own mini ramp to really worry too much at this stage. Dahlen/Pukeboy recommends using 3/4" thickness for the sideboards and 3/8" for the surface. I got 12mm thickness instead. So I decided to use two 12mm sheets for each sideboard to make it strong enough, and then hope that the 12mm would be pliable enough to use for the surface too.

12mm 8'x4' on trailer - exciting stuff


In terms of lumber, I sourced countless planks, all more or less 2"x4" of various lengths, around the farm that I reckon I could use instead of the standard 2"x4" suggested by Dahlen/Pukeboy. Screws and tools were plenty too. So far so good.

The next step was to design the sideboards. I used the string method for drawing the gradient on to the first sheet of plywood and drew the rest of the sideboard outline with a long ruler.


I opted for a 6 1/2' - 2m gradient, as all websites on the topic seem to suggest that is a mellow gradient, suitable for 3' - 1m ramps. The string method is well-explained in the Dahlen/Pukeboy manifestos.

I also spent a bit more time measuring out the exact space in the barn and revised my figures slightly:

Total length: 6.40m
Flat: 1.80m
Each platform is about 0.60m long (ca. 2') - enough to do a rock fakie with trucks all the way to coping and still have breathing space
Height from ground: ca. 1m
Vertical height, coping to flat: ca. 0.90m (3')
Width: 2.44m (8')
Transition gradient ca 2m (ca 6 1/2')

Hopefully it'll just fit (probably a bit snug, but I wanted to use all possible space to ensure a decent length of ramp).

I proceeded to cut out the first sideboard with a jigsaw. I then traced the the cut-out on to the remainder of the sheet and cut that out too. I repeated this process a few more times to leave me with 12 sideboards, all roughly identical. As I'm using thinner plywood than that recommended, I plan to have the outer sides of the four quarterpipes I make to be double layers. The insides will become double once I put the quarterpipes together. To allay confusion, I should add that the Dahlen/Pukeboy method suggests building 4 quarterpipes that, when combined, will make up the two main quarterpipes in each end of the ramp.

A few sideboards cut out


The rest of day one was spent cutting planks to size for the cross joists. I found a whole heap of oak planks that were of a suitable size. Oak is very hard wood and it took a while to saw enough cross joints for the first qaurterpipe.

Day one drew to a close, and I went to bed praying that this project will work.

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