Here's some instructions I put together for another forum.......feel free to ask any ?'s....DUKHTR@yahoo.com
Materials:
4x8 sheet of luan*
bundle of strapping (usually this is 10, 1x3's)
stainless steel course 2" screws
sand paper
flat black exterior latex paint
flat white exterior latex
*luan seems 'floppy' or light, but will be lightweight and very sturdy - mine have lasted many seasons!
Total cost for the first go round is about $42 getting a gallon of black and a quart of white paint - Walmart brand exterior latex is fine. From there the cost slides down to less than $30. I once had a set go at a DU auction for $175, but have sold them without rigging at a couple of shows for $125.
Tools:
miter saw
jig or band saw
sand paper
screw driver
The 4x8 sheet of luan will get you sixteen silhouettes allowing for eight sleds.
Basically the construction is easy......
> cut out the silhouettes, sand them smooth to your liking
> cut the braces at the designated lengths and angles, sand - - when cutting them all out it is easier to keep track of them by putting ‘a’ through ‘h’ or ‘1’ to ‘8’ on each set of braces - it's just a way to keep yourself organized, especially on your first go-round
> screw braces onto silos (two screws per end of brace), and drill 3/8" hole in middle of front brace - be sure the silo is on the outside of the braces - shorter brace in front of silo
> paint
> rig to your preference
Here are the sizings..............
front brace rear brace
A 21" 33
B 22.5 34.5
C 24 36
D 25.5 37.5
E 27 39
F 28.5 40.5
G 30 42
H 31.5 43.5
ends need to mitered at 22.5 degrees
The measurements are to the longest end of the brace and the miter cut starts there. You can decrease the number of sleds as desired, but I suggest starting at the smallest and if you only want 6, stop at the F sled.
TIP: Hank Garvey makes the same sleds...but he angles the front brace up in front and feels this prohibits any 'diving' if moving them into place when already on the water - makes sense so I will try this method next time I make a set.
I tried something different on one set I made. The outside of each silo I painted as eider and the inside as scoter. It really adds a second line of different birds and was very effective. You may wish to seal the luan. I have not and have used my sets for years. They have not warped or lost their rigidity.
