By DIY Andrea in WorkshopWoodworking
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Introduction: Telephone Box K2 (Full Size)
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About: I'm a passionate maker and video creator on YouTube! More About DIY Andrea »
Check the video build here:
Making a Replica of Old English Telephone Box (opens YouTube link in a new tab)
And subscribe here (it's completely free!):
Andrea's Workshop (opens a new tab)
I made this replica and video of K2 back in 2015 but I've never made it for Instructables.
If you want to build it I recommend that you visit Build Eazy (www.buildeazy.com) where you'll find fine detailed plans of the build made by Les Kenny.
It would have been very hard without his plans to build this.
His version is a bit shorter than the one I made since I wanted to have a real size Telephone Box.
Also you'll find some different approach and techniques to the build which I hope will help you build yours.
Thank you Les!
Step 1: The Base
As you'll see I built this in stages and no particular order.
The base was the easiest so I tackled that first.
I made it out of red cedar and added a Guanacaste flooring.
Both woods are great being water resistant.
Nevertheless I applied 3 layers of black paint to the bottom and 4 layers of marine grade varnish to the flooring.
Step 2: The Main Structure
I ripped some stock and glued it up to form thicker posts.
Those I notched to make for a nice moulding.
I also ripped many pieces for mouldings to add later.
This was very time consuming and I had to shape everything by hand since I didn't own a router.
But it was worth it.
On the back I attached the backing of waterproof plywood.
Everything was painted with base vinyl color, then red and then with a coat of SPAR urethane (marine varnish).
The inside of the plywood panel was painted with gloss black.
Finally I attached the flooring to the structure.
Step 3: Door and Window Panels
I made simple frames and then joined the window net using half lap joints.
At the end I sandwiched acrylic glass in between those wooden grids.
I added some trims to the doors and painted all.
Step 4: The Crown (Rooftop)
This was definitely the most complicated and time consuming part of the build but also the most beautiful one.
It looks absolutely spectacular and it's worth to invest your time and do your best to make it look nice!
I did most of the cutting with a jigsaw which took years to finish the crown details.
For the rooftop I used some 3mm MDF which I cut into shapes to close the roof construction.
I later used some plaster just to close some voids.
Later I covered it with some kind of rubber used for making asphalt.
This resulted in 100% waterproof roof and making it fairly lightweight as well, which is important later when you lift it in place. The drawback is that you have to leave it dry for a week at least and it doesn't come as smooth as using cement. If I did it again I would use some fiberglass epoxy mixture.
Step 5: Telephone Sign
I made the box part to fix in the four panels with ''Telephone'' written on them.
I used vinyl cut out letters and transfered rhem with blue tape to the acylic glass.
On the other side I applied frosting spray so the glass is not transparent (you can also sand the back of the acrylic glass with 120 grit sandpaper).
Step 6: Inside Decor
I put a stand with telephone and some old telephone yellow pages and also made a few frames with old pictures from 2nd WW to complete the interior.
You can see how I made the wooden telephone and more decor HERE (opens in a new tab)
Step 7: Final Assembly
I assembled the pieces with help of Miguel.
I was able to put the roof top in place by myself.
With many brackets and hinges I installed the windows and door.
To the door I added the lock so people couldn't get in (and pea inside, or worse)
When everything was in place I added some trim, my signature and caulking to further seal it from water.
I hope you liked it and that it will motivate you to make your own.
Subscribe to my channel here for more videos:
https://www.youtube.com/user/ArzensekAndreaCheers!
Participated in the
Woodworking Contest 2017
