: OK. I have spent a while pondering and this is the method I intend to use to
: build my ES strongback.

: 1. Make a plywood box to avoid warping.
: 2. Simple butt joints throughout as I don't have tools for anything else.

: Unless anyone has any overwhelming reason as to why I shouldn't do it this
: way, then I will be starting cutting on Friday evening.

: Francis.

Hi again Francis

I didn't pan all the way down to your sketch last post. The 3/4" strip idea is of course out of the question. However, I would still suggest the use of screws as a clamping device, rather than all the clamps it would take to hold it all together. It would have to be easier to buy, barrow, or steal a drill than all the clamps that you would need to build this beam. For any glue joint to be strong enough, it has to be "firmly" attached. As was mentioned, merely clamping will cause the material to slide around and give you fits trying to align it all the way down the length.

How are you getting your material cut to the sizes mentioned? However, and whoever is cutting your wood can easily cut the rabbets on a table saw, if that is what they are using. The cleat idea will still work, but, you will need to cut them to the size that will fill the space inside your beam.

May I ask what tools you do have available at your disposal? I hope I don't sound too negative on this, my interested is in getting it done in the easiest, safest and most accurate method available.

Rehd