Building a scaffold (part 1)I needed a scaffold to work on a 16.5' (5m) high ceiling in my big garage workshop. Buying would have cost over $1000, and I didn't want to rent because I didn't want to have to do the work all at once. So I built one out of 2x4s. I bought four 14' (4.2m) long 2x4s and a lot of shorter 2x4s. I also had a few used 2x4s to use.
My design was to make two 4' (1.2m) wide "ladders" out of 2x4s for the uprights. At left, I'm laying it out.
The tenons are 3/4" (19 mm) wide, and I'm using a 3/4" router bit to cut them. There is a lot of material to remove for cutting the tenons, but because the router is cutting side grain, it cuts surprisingly well.
The chips get thrown in all directions, so they are difficult to collect with a dust collector. I put the hose to my cheap dust collector next to the workpiece to at least suck in some of the fine airborne dust.
With the side rails 14' (4.2 m) long, I had to support one end of them, here, on the left of the photo, you can see the rail resting on a hand truck.
This is not my main workshop, so I used an old belt sander, clamped to a 2x4 as a stationary sander of sorts.
The first ladder had some bowing in the side rails, so I used a cargo strap as a band clamp to squeeze it together in the middle.
After that, I started ripping some 8' 2x4's down the middle to make cross braces using my homemade table saw
And this is where I decided to call it a day, so I will finish this scaffold in my next article and video.
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