Aviary Project

PROJECTS BY MIKE

Build this 5' diameter octagonal Aviary for about $300.00

Materials:

QTY. Description

15 6 foot redwood 2x4 studs (Home Depot $5.33 each) $80.00

2 8 foot redwood 2x4 studs (Home Depot $7.95 each) $16.00

50' 2' x 25' rolls of 1/2" wire mesh (two rolls from Home Depot $20.00 each roll) $40.00

2 Box 2" deck screws ($6.50 a box) $13.00

36' 1/2" tongue and groove redwood or cedar (for roof) or plywood and shingles, if the aviary will not be covered by a roofed patio.

8 1' x 2' lexan or glass pane

8 1/4"x 3" lag bolts (.25 each) $2.00

1 bottle Wood glue $4.00

12 2" casters (Harbor Freight $1.99 each) $24.00

Several feathered friends $Priceless

Instructions:

The Base

1. Start by cutting four of the 2"x4"x6' studs to two foot lengths with a miter saw set to cut at 22.5degrees, these will become the base of your Aviary. Test fit the 8 pieces you just cut to make sure they form a perfect octagon.

2. Using a dado blade, make a 5/8" groove down one side of each base approx 1" in from the outside edge, but leave the last piece alone as this will be used for the door later. see picture on left.

3.Carefully mount a caster across the ends of two of the base studs using four wood screws, (the screws will hold both the wheel onto the studs and also hold the two studs together). Use wood glue between the joints before screwing together, repeat for all eight pieces until you have your octagon base completed. (see picture below)

4. Mark and cut a stud across the octagon and secure with two 1/4"x3" lag bolts on each end. You will need to drill 3/4" pilot holes approx 2" deep to accommodate the socket needed to tighten the lag bolts. Mark and cut two more pieces then glue and screw in so that they are perpendicular to the other stud. See picture on right. Lay the base on its back and add another four or more casters in the center of the inner cross braces, this will allow you to walk on the braces when entering the aviary.

The Stringers

5. Now its time to make the stringers that go in between each wall frame. Using your table saw rip 6 of your six foot studs in half.

6. Carefully place one of the ripped stud pieces on one of the corners of your base so that it is centered over both the groove in the base studs and in the middle of the joint that the casters are screwed across. Stringers should be 1/2" from the outside edge of the base. Using a pencil, scribe a line around the stringers' bottom onto the base. Repeat for all eight corners.

7. Using a 3/4" chisel, carefully create a chisel mark on the pencilled line and then using a router and straight bit, route out the corners to the same depth as the groove so that your stringers fit snug into them, then test fit and chisel away any excess wood.

For the two stringers that go on each side of the doorway, you will need to scribe a vertical line that is perpendicular to the doorway entrance so that your hinges and door will close parallel to the stringers.

8. Rip two 3/4" grooves down each stringer at 22.5degree angles so that the wall frames will fit into them. Be careful to flip your stringer opposite end when creating the 2nd groove on each stringer. See picture below.

Stringer

Creating the Framed Walls

9. Start by ripping several 2x4x6' studs into 5/8" thick strips of redwood. You will need to rip about 30 of these. If you prefer not to do so much cutting you can purchase precut 5/8"x2"x 6' lumber from Home Depot; however, they cost about $7.00 each ; whereas you can rip 4 of them from one 2x4 costing you just $5.33. Doing the ripping yourself will save you $23.00 for every four you rip. Since you need 30 you would be saving $175.00.

10. Place two of the 5/8" strips into two of the stringers and place them into position in the base. Carefully measure the distance between the strips (they should be about 19" apart). Then cut your cross pieces using this measurement. You will need to cut 42 of these pieces so make sure you have measured accurately.

11. Start assembling your Aviary walls by drilling or air nailing the frames together. Cross braces can be adjusted any place you prefer. In the picture below I suggest measurements. See picture below:

<--Starting from the top, nail in a brace flush with the top.

<--Measure down 12" and nail in your second brace. (top 12" for framed glass)

<--Measure down 6" more and nail in your third brace. (breeder boxes go between these)

<--Measure down 10" and nail or screw in your fourth brace.

<--Measure down 8" and nail in your fifth brace, (swivel-out food dishes go here)

<--The final brace goes flush on the bottom end.

12. Once you have built 7 of the aviary wall frames you will want to sand and router a 1/4" round bead on the side that will face outside the aviary.

Swivel Feeder Frames

13. Now its time to create your swivel frames for the feed dishes and baths. To do this you will need a drill press so that your holes are drilled squarely in the center. Start by measuring the inside of the frame area where your swiveled frames will fit and cut fourteen 5/8" strips to fit into this area, leaving a 1/4" gap so they will swivel easily and not bind. Using your drill carefully drill a 1/4" hole in the center of your fourteen strips.

14. Cut fourteen short pieces for the vertical sides of your swivel frames. Then air nail the frames together so you have 6 identical swivel feeder frames. Use a router to run a round bead on both sides see picture. Then cut and staple wire mesh to one side.

Here you see a finished swivel tray that will be used for two separate bird baths. The plastic bird baths fit flush into the openings giving the birds in ground swimming pools. A perch was added so they can wait their turn in line.

Wire mesh time

16. Unroll and cut the wire mesh so that approx. 3/4" of the mesh covers the wood frames and then using an electric stapler with 9/16" staples, staple your wire mesh to the inner side of the 7 frames. Be careful you do not staple wire mesh over your swivel frame areas or the breeder box areas if you plan to mount breeder boxes. Staples should be about 5" apart maximum.

17. Using a hammer, pound the stapled down mesh into the redwood so it sits flush with no chance of the birdies getting injured on it.

Putting the walls up

18. Drill two holes into the groove in the base about 6" from each corner for the framed wall sections to be screwed to later.

19. Position your aviary framed sections and stringers into the base. Using 2" deck screws, screw the stringers and frames together and then screw the stringers and frames to the base. Be sure to drill holes before you screw so you don't split the wood. Holes should be drilled in two pairs, one pair in the open swivel feeder area and the other pair in the breeder box area, this way no screws will show on your aviary. See picture below.

Be careful to align the top edges so they are all flush.

Carefully lift up a corner of the aviary about a foot and rest it on a box. Looking underneath the base, locate the holes you drilled previously and secure the walls to the base using 2" deck screws.

to be continued....

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