How to Build Washer Boards

Cut the 1-inch-by-2-inch boards with a circular saw to create the pieces for your washer board frames. You will need four pieces that are 48 inches long, 10 pieces that are 14 1/2 inches long and 18 pieces that are 7 inches long. Note that you will also end up with a few scrap pieces.

Create a rectangle using two 48-inch pieces for the long sides and two 14 1/2-inch pieces for the short sides. Place the shorter pieces between the longer ones to make the overall dimensions 48 inches by 16 inches. Connect the boards using two deck screws at each corner.

Create three interior frames, each using a 14 1/2-inch piece and three 7-inch pieces. For each frame, place two 7-inch pieces perpendicular to the 14 1/2-inch piece, with each located 4 1/2 inches from opposite edges of the longer piece. Place the remaining 7-inch piece at the open end of the two 7-inch pieces already in place. The frame should look like a rectangle centered on a longer base (somewhat like a top hat). Secure the boards using deck screws.

Place one of the interior frames inside the rectangle you built in step 2. The long piece of the interior frame should be 12 inches (center on center) from one of the rectangle's short sides, and the 7-inch pieces should point toward the same side (leaving a roughly 5-inch gap between the interior frame and rectangle). Secure the boards using deck screws.

Place a second interior frame 12 inches from the first and secure it using deck screws. Finally, place the third interior frame 12 inches from the second and secure it as well. The third frame should be roughly 12 inches from the other short side of the rectangle.

Measure, mark and cut 4-inch holes in one of the plywood sheets using a jig saw or hole saw. The center of the first hole should be 8 inches from the short (16-inch) edge of the plywood and 8 inches from each long edge (i.e., centered). The center of the second hole should be 12 inches from the center of the first, and the center of the third hole should be 12 inches from the center of the second. This will place the center of the third hole some 16 inches from the other short edge of the plywood.

Attach the plywood sheet to the frame you built in steps 2 through 5. Use deck screws to secure the plywood to the exterior rectangle and the interior frames. Be sure to sink the screws deeply so they do not protrude above the surface of the plywood.

Repeat steps 2 through 7 to create a second washer board.

Drill a hole in the center of the short edge of each washer board that is farthest from the holes (i.e., 16 inches from the third hole). The hole should be big enough to accommodate the rope but small enough to prevent a knot from passing through.

Tie a knot in the end of the rope, leaving a few inches of extra rope beyond the knot. Feed the rope through one of the holes you drilled in step 9, with the knot on the inside of the washer board.

Pull the rope so the knot is tight against the inside of the washer board, and measure and mark 10 feet of distance. Feed the edge of the rope through the hole in the other washer board (working from the outside in), and tie a knot that will allow the washer boards to be 10 feet apart when the rope between them is stretched taut. Cut off the extra rope, leaving a few inches beyond the knot.