DIY 3-in-1 WOOD PLYO BOX for $35! {Fitness/Tutorials}

BOX2I have been wanting to post about this DIY for FORRRREVVVVVERRRRR…but life happens and I could never bribe Jeff enough to get him to write down the tutorial for this amazing PLYO BOX!…until the other day!! (the bribe included chocolate milk shakes and other things not appropriate to blog about…so we will just keep it at that! mmmkay)

Without further ado…in the words of my amazingly hot and talented husband, here is the step by step tutorial for your 3-in-1 wood plyo box!

Of all the DIY projects that I’ve done this has to be one of the hardest projects! It was worth it though because it serves a purpose and I saved over $100 by making me own.What makes this style of box different than simply cutting pieces of wood and building a box is that the pieces interlock with each other creating a nice strong box that doesn’t require any interior bracing or framework.So let’s begin (hopefully everything makes sense).  What makes this box special is that you have 3 different height options 20”, 24”, & 30”.

You’ll notice in the pictures that I made 5 boxes.  I actually made them for my brother in-law to use in his CrossFit gym.CrossFit Edify

Tools Needed

1.     Table Saw & or Skill Saw

2.     Nail Gun (16 gauge @ 2” long)

3.     Drill

4.     Jig Saw

5.     Wood Glue

6.     Tape Measure/Framing Square

Detailed Step List

1.     Purchase a sheet of 4’x8’ ¾” Plywood.  I got mine from Home Depot for around $35.  1 Sheet will make 1 Ply Box

2.     You’ll need the following pieces cut at the different dimensions. 

a.     2 – 20”x24”

b.     2 – 20”x30”

c.      2 – 24”x30”

3.     Once you’ve got your pieces cut you’ll need to cut out the notches so the sections can interlock with each other.  When you cut out the notches make sure you cut back the same thickness as the plywood.  Don’t just cut back the ¾”, you need to measure.  As for how long your notches should be, measure 8” from the theoretical edge of the wood then cut out the section with a jig saw.  Follow the picture of the three different sized pieces to get your pattern and an idea of what each piece needs to look like.  Disclaimer: this is the hardest part so take your time with the measurements and the cutting.  Following the pattern from the picture and it will work. 

4.     Once the pieces are cut and notches are ready you can now assemble. Start by laying one 24”x30” on a flat surface.  Then apply some glue along the edges where the other pieces will join.  Now start putting the puzzle together by starting with the sides then finishing with the top.  I would put only 1 or 2 nails in each section until I have all the pieces together.  You’ll have a few gaps and need to put your muscle into it to get it to squeeze and fit together just right.  Once your satisfied you can then finish nailing the box together.

5.     Once my box was finished I took my router to all the edges to give a nice rounded edge.

6.     One convenience I put on the boxes were openings on the side for you hands.  To do these I drew out the size I wanted, drilled a hole for the jig saw blade to fit in and then cut out the section.  You can do this step at any time.  Just make sure you do it on the 20”x24” piece. I then sanded out the inside of the hand holds and sanded all the edges one more time to ensure they were rounded and smooth! You don’t want abrupt edges when you are using these puppies! That just calls from some serious shin injuries!

BOX

BOX5

BOX8BOX6BOX90  BOX77  BOX778

BOX44

Email me for any questions (simplysadiejane@yahoo.com)

Make sure to check out our DIY PULL UP BAR and DIY SQUAT RACK!

AND

our 6 WEEK AT-HOME CROSSFIT INSPIRED WORKOUTS

AND

if you ever have any questions about certain workouts, refer to THIS POST!

XOXO

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Showing 22 comments
  • Chelsea
    Reply

    Thanks so much for getting him to tell you how to do this! My husband said he would make me one and now he can!!

  • Lexie
    Reply

    I love this I can’t wait to make this!!

  • Scott Simpson
    Reply

    I’m definitely making one of these boxes today. I like the simple idea of multiple heights in one box. My 13 year old and I have started working out and I was thinking of building multiple boxes for different heights. Great idea. Thanks.

  • Nelson
    Reply

    Great work on the project. Would you suggest reinforcing the box with cross sections inside or is it pretty sturdy as is?

    • Sadie Jane Sabin
      Reply

      Sounds like a great idea!! You definitely could do that! We didn’t and it works great!

  • Hair Salons In Bradenton FL
    Reply

    I was suggested this blog via my cousin. I’m not sure whether
    or not this publish is written through him as no one else understand such detailed about my difficulty.
    You’re wonderful! Thank you!

  • Sid
    Reply

    Love this! I wanna make my own of this but 30″ is to high for me. Maybe I will make 16 x 20 x 24″ plyo box. How many box I could make in a sheet (4′ x 8′ x 3/4″) plywood?

    • B
      Reply

      You will have several small scrap pieces from a full 4’x8′ panel.

  • Nicolas
    Reply

    Hello, thank a lot for sharing this. I saw it yesterday and i’ve dédiced to try one this afternoon …. i’m in the building process

    i’ve made all cuts …. but its not perfect enought for me – the plywood tickness is nut the same everywhere …. aghrr :( – …. some corrections will be needded before assembling.

    few tips for those who’ll try : you need a good jigsaw ^^ , and i think if i do it again i’ll cut a little more than the thickness of the plywood and rabbet the exceeding parts.
    Its not really difficult but not so easy as it seem, be carrefull and take your time (Jeff must be very good when it comes to woodcraft).

    I’ll assemble tomorow and i don’t have a nailgun … the hammer part gonna be a little difficult.
    But I’ve made a test without bond and nails and that will do (after corrections)….. a very nice plyo wood box !!!

    Regards
    p.s. i’m french so …. i’m so sorry for the spelling mistakes.

  • Alex
    Reply

    is there enough clearance for a slightly bigger roundover on the edges?

    • Nicolas
      Reply

      yes, but i think its not needed ….

      the box is very nice and a friend of mine who weight 250 pounds didnt made it even bend ….
      very strong plyobox ^^

  • David Fournier
    Reply

    Is each piece to be cut 8 inches from the edge the same per step #3?

    Just want to make sure before I waste a piece:>)

    Once you’ve got your pieces cut you’ll need to cut out the notches so the sections can interlock with each other. When you cut out the notches make sure you cut back the same thickness as the plywood. Don’t just cut back the ¾”, you need to measure. As for how long your notches should be, measure 8” from the theoretical edge of the wood then cut out the section with a jig saw. Follow the picture of the three different sized pieces to get your pattern and an idea of what each piece needs to look like. Disclaimer: this is the hardest part so take your time with the measurements and the cutting. Following the pattern from the picture and it will work.

  • Kevin Tye
    Reply

    Great tutorial. I built the box and it is super sturdy (I weigh 200lbs) with no additional infrastructure. Here’s some things I learned the hard way while building my box:

    1. Don’t have Home Depot cut your plywood on their vertical panel saw, it’s not very exact and makes for an uneven box.

    2. Take your time on the notches and cuts, a GOOD jigsaw is essential… I used a $30 Ryobi and I regretted it.

    3. If you know what you’re doing, a skill saw may be a better choice for the “male” sides of your notches.

  • Cody
    Reply

    For the plywood did you use ACX or BCX?

    • sadie
      Reply

      I am not sure to be honest, we just used typical plywood you would be at Lowes or Home Depot, 3/4″ thick

  • CHRIS
    Reply

    Very sturdy looking box. I will stress though, please, please wear your safety glasses when using your power tools. Shit happens. But other than that this is a great tutorial.

    • sadie
      Reply

      Couldn’t agree more! Thank you for your feedback! I will get on my husband STAT about that!

  • Sunil
    Reply

    I need a plyo box Plz.. Call me on 9870777420

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