Blue Bird Box by Todd A Carlson, Hudsonville, MI, carlsont@gvsu.edu
See cutting plan for cutting all pieces out of a single six foot 1x6 cedar board. Pieces can be cut in different order to avoid knot holes is bad places (such as where the entrance
hole is). The back piece can be cut a few inches shorter if you run short of wood There will be very little waste. First assemble the roof. Don’t drill the pin hole until the box is
assembled. I use hardwood trim nails (1½” 4d) for assembly. Nail and glue the roof boards together first and then attach the cleats. Be sure the distance between the outside
edges of the cleats is slightly less than the with of the side boards so the cleats will slide inside the box assembly. Next assemble the box. Nail the front to the bottom first.
Then attach the sides, leaving a gap between the top edge of the sides and the top edges of the front for ventilation. Before nailing the back, set the roof assembly in place and
adjust the back so the roof is level. Next drill holes through the front and back for removable pins to secure the roof. Attach the pipe straps to the back. Cut 2 to 3 feet off the
metal conduit and drive into the ground. Mount the box with the pipe straps. You may need to put a shim between the pipe and the box under the strap to get a tight fit.
Roof Assembly
Front View
Roof
Roof Cleat
glue or calk this joint
for waterproofing
drill matching holes in
front, back, and cleats
for removable pins to
Roof
secure roof
hole for removable
pins to secure roof
Box Assembly
trim off extenting
point if desired
Top View
Front View
gap for roof
ventilation
Top View
Front
Roof
Roof
Front
Cleat
5 1/2"
cleats are spced
to fit inside
box assembly
Side
Bottom
Side
Side
Side
corners cut off of
bottom provide
ventilation
Back
Bottom
Cleat
1 1/2"
1/2"
Back
(side view)
45 deg
Cutting Plan for 6 foot cedar 1x6
16"
12 1/2"
back
roof
8"
8"
45 deg bevel cut
4"
8 7/8"
Side
roof
12 1/2"
11"
Side
5 1/2"
Sides (2X)
8 7/8"
8 7/8"
2 3/4"
45 deg
2 3/4"
not to scale
45 deg
Roof Cleat
Back
3/4" pipe straps screwed to back
2 3/4"
2 3/4"
Front
10 foot long 3/4" diameter
galvanized electrical conduit
5 1/2 "
6 1/2"
2 1/4"
2 3/4"
oval opening made from
two 1 3/8" diameter holes
Roof Cleat
11"
16"
8"
5 1/2"
7 3/16"
7/8"
1 3/8"
90 deg
90 deg
2 3/4"
8 1/4"
1/2"
Roof (2X)
12 1/2"
Bottom
4"
5 1/2 "
5 1/2 "