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How to make a Bumblebee box from a recycled pallet
by Robin Morris –
  Yatton Area Bee Project
Tools required:
•
Hand saw
•
Drill (for pilot holes for screws)
•
Wood glue
•
Screws - size 4 x 50mm or longer (imperial 8 x 2”)
Step 1 – Preparation
The easiest way is to cut the planks frombetween the bars of the pallet as shown. Makethe cuts square (use a set square if possible)and as near to the bar as you can to maximisethe timber you use. You will need to cut thefollowing planks:
•
3 x roof pieces (A) - make these eachthe same length and as long as your cutplanks will permit
•
6 x floor/sides pieces (B) – cut these40mm shorter than your roof pieces A
•
4 x end lengths (C) – these needs to be the width of your planks x 2 .If you choose to add the optional vestibule you also need:
•
2 x vestibule pieces (D) – again these need to be the width of your planks x 2minus 3mm (or the thickness of your perspex)
•
2 x off-cuts
•
piece of perspex
Step 2 – Floor 
To make the floor take two equal lengths of thefloor/side pieces (B).Drill 4 pilot holes in the corners of each piece.Use another plank to mark the width along eachend (see illustration) then drill the holesmidway.Glue the butting sides and place together as inthe illustration.
Step 3 – Add the Front
To make the front and back ends take one of the side/floor pieces (B).Use a hole cutter to cut a 25mm entrance holein one end. If you don't have a hole cutter.....(pto)
 
…......cut a 25 x 25mm notch from the corner of the front section.Glue and screw front to one end of floor.
Step 4 – Add the back
Take another of the side/floor pieces (B) andglue and screw it to the back
Step 5 – Add lower sides
To make bottom sides cut 2 further lengths thesame as the floor, glue and screw these to thesides.Note that the top surface of the sides does notcome up to the ends. This is deliberate.
Step 6 – Add upper sides
Take two more floor/side pieces (B), glue andscrew them in place as shown.Ensure that one of the pilot holes allows you toscrew the side pieces to front/back pieces wherethey overlap – see red arrow.
 
Step 7 – Add upper ends
These will need to be cut lengthwise first. To do thisput in place, draw a line joining the tops of eachside then cut off the edge (shown on red inillustration).Once cut glue and screw in place.
Step 8 – Add vestibule (optional)
Whilst a vestibule is not essential it isrecommended.To make, take 2 lengths of planking and standinside your box about 40mm from the entrance. Cutlevel with the top or, if you are adding a viewingwindow, cut to be 3mm shorter than the top.Cut a 25mm hole in one piece and position to bethe opposite side to the entrance hole. Again if youdon't have a hole cutter make a 25mm notch in onecorner.When cut to size, glue and screw in place.
Step 9 – Add viewing window (optional)
Using a couple of off-cut pieces of wood glueviewing window supports 3mm below the top at thetwo rear corners. Together with the vestibuleentrance, these will support the perspex viewingwindow.If you choose not to add a vestibule then you willalso need to add two more supports to the frontcorners to support the window.Cut a piece of 2mm perspex to fit the insidedimensions of your box. Place this to rest on thevestibule and corner supports.
NB: Please don't use a window as an excuse tokeep peeking in. Best to only rarely look asfrequent disturbance will cause your bees toabscond.
vestibule
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uploaded a new revision for this document (#4)

11 / 12 / 2009

uploaded a new revision for this document (#3)

11 / 11 / 2009

uploaded a new revision for this document (#2)

11 / 11 / 2009

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11 / 11 / 2009
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