Wood Working

UPS Enclosure which is weather proof – Build It

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This week I decided to make a UPS enclosure which also acts as a mini garden. It’s going to be kept outside so it has to be weather proof. Let me show you how I did it.

Setting up right angles.

Setting up right angles

I have all the cut pieces ready. The dimensions change depending on how big your ups enclosure needs to be. To fix the face frames at right angle I am using a square and two blocks of wood. I carefully position them on my work table, check for squareness and screw them to my table.

Face frames are made with 12mm plywood.

Face frames are made with 12mm plywood.

I place the 12mm plywood face frame against these blocks of wood. I pour some fevicol wood glue and apply a gentle amount on the plywood. Then I place a 6mm plywood against the block of wood to make sure everything square. Because the weight of the garden will be taken by the 12mm face frame I just used 6mm plywood to make the sides of the box.

Using small Philips CSK head screws I attach the sides to the face frame.

Using small Philips CSK head screws I attach the sides to the face frame.

I attached the plywood to the face frame with small Philip head screws. I repeat the same steps to attach the other two face frame to the 6mm plywood. This makes one side of the ups enclosure. Again I attach it with some screws.

Both the sides are held at right angles.

Both the sides are held at right angles.

With all three sides made. I position one next to other. Please notice that I screwed the face frame from inside the box to keep things tidy. Then I used my 3D printer corner clamp to help it in place while I screw both the sides together. The corner clamp does a good job of holding the sides in place.

Attaching the sides using one inch screws.

Attaching the sides using one inch screws.

I used one inch screws to attach the sides. I do not have pocket jig so I had to screw them to the end grain of the plywood. This joint was pretty strong. Once I have attached the side half way I flip it and screw in to attach the rest of the sides of the  ups enclosure.

The sides are held temporarily using 3D printed corner clamp.

The sides are held temporarily using 3D printed corner clamp.

I repeat the process to attach the third side. Because my work table was too small I used the floor to attach everything together. I first attach the side with screw in the middle. This helped to keep the edge flush while I attached the rest of the box. Flipping the ups enclosure down helped me to drive the screws easier.

18mm plywood is used to attach the top to the sides.

18mm plywood is used to attach the top to the sides.

To attach the top I used a 18mm plywood. This will help carry all the weight of the flower pots. I left a bit of over hang on the sides because I needed a wider base for the garden. After positioning the top on the ups enclosure I use a straight edge and drew lines marking the centre of the plywood below. This will help me in guiding the drill holes when I attach the top with screws.

Pilot holes are drilled with 3mm drill bit.

Pilot holes are drilled with 3mm drill bit.

I first use a 3mm drill bit to drive some pilot holes. This will ensure that the plywood does not split when I attach it with some screws. I used inch and half Philips CSK head screws to attach the top to the box.

Using silicon the box is sealed so no water can get in.

Using silicon the box is sealed so no water can get in.

Then I painted wood primer only to the outside of the box. Because this box will be exposed to the natural elements I apply a good amount of silicon to keep water from coming in. I seal both the inside and the outside. I applied two coats of Asian Paints Satin paints so it weather proof. Time to push the ups enclosure on top of the UPS.

Watch how UPS Enclosure is made:

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