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Climbing Arch Instructions
Designed in the same style as a Climbing
Triangle, this arch provides exciting
challenges for your child to develop skills
and confidence in his or her environment.
“Large” Shown below:
These plans include instructions and details
to make either or both sizes as shown
Hardware & Materials:
GRK or SPAX brand #8 x 2-½”
(or 2”) cabinet screw, or alt.
○ (22) for “Small” Arch
○ (26) for “Large” Arch
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○
○
“Small” and “Large” can nest:
GRK: #113079
SPAX: #4281670400604
1” Diameter dowels
○ (11) for “Small” arch,
24” long
○ (13) for “Large” arch, 36” long
(2) 2 ft x 4 ft pieces of ¾” plywood
Sandpaper
The finish of your choice, I
recommend shellac or polyurethane
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●
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Tools:
Jig-Saw or Band-Saw
Router with ¼” radius bits (optional)
Drill or drill press with 5/32” (or
3/16”) bit, and 1” forstner bit
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Components:
1. Small Arc (qty 2)
2. Large Arc (qty 2)
3. Rungs (“Short” and “Long”)
Notes:
Please make sure to pick a high-quality
plywood with at least 7 plys. I usually use a
13-ply maple or baltic birch for many
projects such as this
Revision: 20201028
SAFETY NOTE​: Always provide guidance for safe use and
supervision when your child(ren) are using this item
DIY Small and Large CLIMBING Arch Instructions
Page 1 of 7
DRAWINGS, DESIGNS, AND INSTRUCTIONS ARE THE PROPERTY OF ​WESTRICK WOODEN WORKS, LLC​ AND MAY NOT BE REPRODUCED OR DISTRIBUTED
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Step #1: Layout ​Arc​ Cut-Lines
You can decide to make either the Small,
the Large, or both Arches.
Both the small and large arches can be cut
from two 2-foot x 4-foot pieces of plywood.
The small arch fits inside the large arch if
you are making both.
Start with a 24” x 48” piece of
plywood, these dimensions do not
need to be exact
Mark a point “C” for center in the
middle of the right-hand side as
shown in the diagram.
The cut-lines are made by drawing
multiple arcs starting from the point
noted “C”
○ Small Arc: 14-⅜ (inner)
○ Small Arc: 16
(center)
○ Small Arc: 17-⅝ (outer)
○ Large Arc: 18
(inner)
○ Large Arc: 20 (center)
○ Large Arc: 22
(outer)
Repeat to make second set of
arches, optionally, you can wait until
after you cut out the first arch, and
trace the second.
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Note:
There are various ways to draw the arcs,
some people prefer string around a pin at
the center, and hold a pencil at the right
distance against the string.
Another option is to use a scrap piece of
wood, about 24” long, drill a small hole
about 1” from one end, then measure from
that hole and make a mark for each of the
above dimensions, drilling another hole for a
pencil. Pin the initial hole at point ‘C’ with a
small nail or drill bit, and draw each arc with
a pencil or marker
Revision: 20201028
DIY Small and Large CLIMBING Arch Instructions
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DRAWINGS, DESIGNS, AND INSTRUCTIONS ARE THE PROPERTY OF ​WESTRICK WOODEN WORKS, LLC​ AND MAY NOT BE REPRODUCED OR DISTRIBUTED
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Step #2: Mark R
​ ungs
Next you will mark all of the points to drill
holes for the rungs. Continue to refer to the
diagram on the previous page.
Start at point ‘A’ and measure along
the centerline arc either 4-½” for the
large arch, or 4-¼” for the small arch
● Make another mark at this point,
then starting from this new point,
measure and mark the next point,
repeat for all marks.
Note: ​Each point is measured from the last
one marked.
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Step #3: Draw Corner Radii
Draw a 1” radius at each of the
corners
This does not have to be exact. I typically
find an old bottle, dowel, or some other
round object in the right size to trace.
Remember, for a 1” radius, find something
about 2” in diameter.
●
Step #4: Drill Holes
The rungs are held securely in a ¼” deep, 1”
diameter hole. This allows for a good glue
connection, and is much stronger than using
screws alone. Without this recessed hole for
each rung, the rung could split and
potentially expose the screw end.
● Using a 1” diameter Forstner bit, drill
a hole at each marked location,
approximately ¼” deep. This is
easiest in a drill press that can
control the depth, but you can use a
hand drill carefully as well.
● Next, drill a 5/32” (or 3/16”) hole
through the plywood at the center
of each of the 1” diameter holes
Revision: 20201028
DIY Small and Large CLIMBING Arch Instructions
Page 3 of 7
DRAWINGS, DESIGNS, AND INSTRUCTIONS ARE THE PROPERTY OF ​WESTRICK WOODEN WORKS, LLC​ AND MAY NOT BE REPRODUCED OR DISTRIBUTED
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Step #5: Cut Out Each ​Arc
Using a jig-saw with an appropriate
fine-tooth blade, cut out each A
​ rc ​from the
plywood.
After cutting, make sure each edge is
smooth. Use a file, a block of wood and
sandpaper, or a power sander to smooth
each cut edge.
After all edges are smooth, apply a ¼” radius
to all outer edges using a router and ¼”
roundover bit. This can also be done by
hand with a file, sandpaper, and sander.
Sand all surfaces of the plywood, this is
easier to do now than after assembly
Step #6: Cut ​Rungs t​ o Length
Using a miter-saw or other suitable saw, cut
the appropriate number of rungs to length.
● To make the ‘Small’ Arch, cut (11) 24”
long rungs
● To make the “Large” Arch, cut (13)
36” long rungs
● Using a piece of sandpaper, smooth
each cut end, and take off the sharp
corner. This will make gluing and
assembly easier
These lengths can be adjusted slightly, and
do not need to be exactly 24” or 36” long,
but make sure that all the rungs for each
arch end up the same.
Revision: 20201028
DIY Small and Large CLIMBING Arch Instructions
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DRAWINGS, DESIGNS, AND INSTRUCTIONS ARE THE PROPERTY OF ​WESTRICK WOODEN WORKS, LLC​ AND MAY NOT BE REPRODUCED OR DISTRIBUTED
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Step #7a: Assembly
Starting with one cut-out A
​ rc​, the rungs will
be glued into each hole and secured with a
screw.
● First, test-fit the rungs into the holes
to ensure a good fit
● Apply a small amount of wood-glue
to the bottom of each 1” diameter
hole, spread evenly with a brush
● Place the Arc on a sturdy surface
(floor or workbench) and apply a
couple blows with a mallet/hammer
or even a scrap of wood to ensure
the rung is fully seated.
● Turn the ​arc a​ nd ​rung ​over, and Use
a drill or power-screwdriver to drive
a screw through the hole in the
plywood into the end of the rung.
Repeat for each rung
NOTES:
●
DO NOT TIGHTEN fully with the
drill, finish tightening each screw by
hand to ensure it does not strip.
●
The GRK or SPAX brand screws that
I have specified do not require a
pre-drilled pilot hole. If you use a
different type of screw, please check
to see if a pilot will be required.
Screws made by KREG would also
work, and do not need a pre-drilled
pilot hole, but they have a slightly
smaller head diameter.
Revision: 20201028
DIY Small and Large CLIMBING Arch Instructions
Page 5 of 7
DRAWINGS, DESIGNS, AND INSTRUCTIONS ARE THE PROPERTY OF ​WESTRICK WOODEN WORKS, LLC​ AND MAY NOT BE REPRODUCED OR DISTRIBUTED
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WestrickWoodenWorks.com
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Step 7b: Assembly 2.0
This step involves attaching the second ​Arc
side to all of the r​ ungs​ from the last step. It
is a little bit trickier because you have to line
up all the rungs and holes at once, but it is
quite doable. Do not apply too much glue,
otherwise it will begin running out of the
holes while you work.
● Place the​ arc​ and r​ ungs​ from the
previous step on a sturdy surface
(floor) with the loose ends of the
rungs​ pointed upwards
● Take the remaining ​Arc​ side (the one
without any rungs in it) and apply a
small amount of glue inside each of
the 1” diameter holes. Spread
evenly with a brush.
● Position this a​ rc ​over the ends of the
rungs, and slowly begin aligning
each rung to the corresponding hole,
working from one end.
● Apply pressure or light taps with a
mallet to seat each rung in the holes,
work just a small amount at a time,
back and forth from the first rung to
the last.
● Once all rungs are inserted and fully
seated, drive a screw into each to
secure it, and tighten (by hand)
Notes:
Make sure to round the ends of each ​rung
with sandpaper. Removing the sharp edges
makes aligning in this step much easier.
Revision: 20201028
DIY Small and Large CLIMBING Arch Instructions
Page 6 of 7
DRAWINGS, DESIGNS, AND INSTRUCTIONS ARE THE PROPERTY OF ​WESTRICK WOODEN WORKS, LLC​ AND MAY NOT BE REPRODUCED OR DISTRIBUTED
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WestrickWoodenWorks.com
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Step #8: Finish!
Check that all surfaces, edges, and corners
are rounded and smooth.
Apply a finish of your choice, I recommend
shellac or polyurethane. Polyurethane will
give a more durable surface. Oil-based is
the most durable, but water based
polyurethane works very well also.
Apply 2-3 coats, sanding lightly in between
SAFETY NOTE​: Always provide guidance for
safe use and supervision when your
child(ren) are using this item
Revision: 20201028
DIY Small and Large CLIMBING Arch Instructions
Page 7 of 7
DRAWINGS, DESIGNS, AND INSTRUCTIONS ARE THE PROPERTY OF ​WESTRICK WOODEN WORKS, LLC​ AND MAY NOT BE REPRODUCED OR DISTRIBUTED