Huff's new custom cage

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I started building this cage in June 2002. I lost my momentum for a few months (varnishing is BORING), but I found a second wind in October and finished it! Huff moved in October 5th, and seems to like it, although she's a little jumpy from the change. Following are some pics from the building process and a little description, which might help other amateur carpenters out there.


Tools you should own before starting a project like this:



The cage is 4X2X1.5. I used 3/8" plywood (certified sanded on one side for the interior) to build the back and bottom. I had Home Depot cut a full sheet of plywood in the store for me into two 2X4 and two 1.5X4 sections (makes two cages). I used Minwax Polycrylic varnish (Satin finish) in three coats to seal the wood. This involved hours spent applying varnish. At least I got to enjoy the fresh air and birdsong on my balcony.


The certified sanded side is gorgeous. Be sure to allow the varnish to dry between coats, and sand with very fine sandpaper after the first coat.


I bought lengths of 2X4s, 2X2s and 1X2s for various parts. I also bought moulding for the screen frames for the ends and top. I cut the lengths at home with the backsaw. Be sure to purchase very straight boards, and measure twice before cutting! The wood was sanded thoroughly before varnishing. More boring work, so bring a friend for conversation. Important tip! 2X4s are not exactly 2" by 4"! Be sure to compensate for this in your measurements!


I made an inner frame out of 2X4s for sturdiness, since I want to stack two cages eventually. The 2X4s are connected using metal L- and T-braces, with 2" screws put in on the ends for added sturdiness (that part sucked!). Be sure to use the angle to check all of your alignments.


Here you see an end piece on the left and the center piece to the right. These will be connected with 2X2s. (The pieces are just sitting on the bottom piece - I didn't screw that on until the frame was complete.)


Finished frame from above.


Finished frame from the front. I wanted this built so it would be possible to break down if it had to be done. It could be done, it would just need a lot of elbow grease and new screws to replace the old ones I partially stripped. :-)


Looking through the frame. (Wow, my kitchen's messy!)


T-brace on the center frame. Note the 2 screws put in from the front to reinforce it. You need to use a countersink on the pilot holes to get the flat-head screws flush. I used round-head screws on the metal braces.


L-brace on the end corner. The braces were long enough (6") to be attached to the 2X2s as well. The drawback was that, since I put them on top to conceal them, I eventually had to drill holes through them to attach the screen frame. I used a bit for drilling metal, and really, it was easier than I thought it would be.


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