Technical Applications Technical Applications Design Challenge: Design Challenge:

Mr. WetzelMr. Wetzel(Mr. G’s project)(Mr. G’s project)

Project Project Garden GateGarden Gate

Why?Why? Existing fence is rusty old chicken wire.Existing fence is rusty old chicken wire. No gate, have to climb over fence to get into No gate, have to climb over fence to get into

garden.garden. Looks terrible. Mrs. G. nags me to fix it.Looks terrible. Mrs. G. nags me to fix it.

Problem:Problem:My 4 1/2’ x 15’ garden has and old rusty, broken My 4 1/2’ x 15’ garden has and old rusty, broken fence with no gate.fence with no gate.Construct a new fence with a gate.Construct a new fence with a gate.

Specifications (requirements)Specifications (requirements) Utilize existing materials saved from other projects.Utilize existing materials saved from other projects. Maximum cost of materials: $0Maximum cost of materials: $0 Complete project within 16 hrs. (2 Saturdays)Complete project within 16 hrs. (2 Saturdays) Must use weather resistant materials. Must be open Must use weather resistant materials. Must be open

enough to let in sunlight all day.enough to let in sunlight all day. Width: 15’, depth: 4 1/2’, Height: 3’. (foraging deer Width: 15’, depth: 4 1/2’, Height: 3’. (foraging deer

not really a problem).not really a problem). Install a functional gate for easy access.Install a functional gate for easy access. Only install fence on 3 sides. Can use wall of house Only install fence on 3 sides. Can use wall of house

and air conditioner as part of fencing.and air conditioner as part of fencing.

Exploring Ideas

• Idea #1 Red Cedar Accent Fencing

Pro: looks great!!!

Con: Do not have the material, out of budget. Too time consuming to construct.

***Include (staple into your report) freehand sketches using pencil and graph paper with explanations of good and/or bad features. Some projects will require school approved software/simulation for designing. Explain the s/w, how it works, your results. Include all output in your report.

• Idea #2 White vinyl Fencing and gatePro: Weather resistant, no painting needed. Wide gate to carry out those huge pumpkins!Con: Do not have the material, out of budget.

• Idea # 3 buildeasy.com website, easy instructions for do-it-yourselfers like me.

Pro: just what I’m looking for.

Con: I will have to modify their design to fit the materials I have.

Making: I constructed the fencing and gate myself using left over

supplies from several other projects. The fence posts were ripped from 2 x 6 pressure treated lumber from my rear deck. The gate and perimeter toe

boards were left over from my neighbor’s cedar patio fence. The green plastic fencing was left over from a protective shrubbery fence project.

• Remove old wire fence and rotten fence posts.• Stretch a guide line length of garden and

4 1/2’ parallel with house.• Rip 2 x 6 boards on table saw 2” x 2” for posts.

Cross cut to length of 4 1/2’. Make 10 posts.• Using hatchet, place end of posts on scrap wood and

shape one end to point, for easier hammering into ground.• Begin by setting the two posts for the gate 19” apart (add 1” clearance for

18” wide gate). Hammer in straight with sledge hammer. Constantly stop and check for plumb using a level. Stop when approximately when 12” is in ground. 3 1/2’ should be above ground.

• Layout remaining posts evenly spaced…about 3’ apart. Drive into ground same as for gate posts.

Making: (continued)

• Install 4” x 1” x 8’ cedar toe boards to bottom of fence posts. Pilot drill 1/8” hole, use #8 x 2” galvanized deck screws. 2 screws/ post. Toe boards will keep in garden soil and prevent animals from burrowing under fence. Cedar is a rot resistant wood.

• Cut 2 x 2 wood braces on corners and gate to provide support. Install diagonally and use 3” length galvanized wood screws. Always pilot drill. Used electric hand drill and good old Phillips screw driver by hand.

• Attach heavy duty green plastic fencing to posts using plastic coated copper wire salvaged from phone company office installation. Copper wire will not rust and is strong if wrapped several times around post. Cut fence material with hand metal shears.

• Begin gate construction. Disassemble section of 8’ board-on-board cedar fence to obtain materials.

• Use tape measure and tri-square to layout. Cut two 8’ boards in half using cross-cut hand saw to create four 4’ gate boards. Trim two boards with hand saw to have matching chamfered ends.

• Measure and cut two 2” x 3” horizontal cross members. Use combo-square and hand saw. Hold in vice on work bench while cutting.

Making: (continued)

• Using combo square and tape measure, create guide lines on gate boards 12” from top and bottom to position horizontal cross members.

• Clamp with c-clamp top cross member perpendicular to one gate board with end even with board. Pilot drill and screw board to cross member with two 2” galv wood screws to prevent movement.

• Repeat with bottom cross member.• Position another gate board to opposite side of

cross member. Clamp, drill, screw and perform work same as first board.

• The gate now looks like a rectangular frame. Place the two middle gate boards evenly spaced, about 1 3/8” apart. Clamp, drill and screw together.

• Flip the gate upside down, measure and cut a diagonal cross member. To find the needed angle, lay the wood into position and trace. You can also use a sliding t-bevel to find your angle. Clamp, drill and screw together the cross brace.

Gate rear view

Diagonal support

CrossmemberGate board

Making: Hinge• Using two old galvanized hinges from a garage door, scribe and cut away supports to

permit 90° bend on right side. Clamp in vise, use hacksaw.• Measure and bend left side of hinge to wrap around gate post and provide rigid

attachment. Drill new 1/8” hole on left side using drill press. Clamp in vise.

• Attach hinges using galv wood screws and washers to prevent screws from popping out of oval hinge holes. Always pilot drill first.

• Hasp. Not the most technical device, but it will work temporarily until I find something better laying around in my basement or garage. Create a loop of plastic coated copper phone wire.

Cut away here

Bend and drill

washer

Cheapo hasp

Testing• The project is a success? If only I can stop those “attack” pumpkins.• The fence and gate have held up well for several years now.• I have kept to my budget, using only existing materials. • Wife and neighbors are pleased. • One nice feature is, I can un-attach the left side fence and swing it out of the

way. This permits burying my fig tree to prevent any frost damage.

Fig tree

Solution

• This was a very rewarding project. I was able to complete it within my allocated time frame of two Saturdays.

• It was great because it cost nothing to build, and I was able to use up some supplies left over from previous projects.

• It must be working because I have not found any evidence of intruding varmints. Now if only it can keep those pumpkins from escaping.

• The fence is not really strong enough to hold up the weight of the pumpkin vines. I don’t plan on letting pumpkins grow again. Stick to tomatoes and figs.

Improved security

(Sketches of improved design should go here)

Good Luck!!!!