Thanks for the comments!
NanoAmbiance, Here's what I did:
- Used regular 2X4's for the frame.
- Glued each joint and used rust proof 3-inch deck screws (Deck Mate brand from HD).
- Installed the flooring from 1/2 inch regular plywood.
- Installed the top from 1/2 inch regular plywood.
- Used caulk to seal all joints between 2x4's as well as where the plywood flooring meets up to the stand.
- Primed the entire frame with Kilz brand primer.
- Used 1X6 pine boards as well as 1/2inch standard plywood for part of the sides.
- Added some moulding.
- I attached the shell to the 2x4's by using a nail gun with 2inch brads (lots of them).
- I then primed all the shell with a dark tinted primer (2 coats) and then painted over that with a high quality semi-gloss oil-based paint (2 coats).
- I made the doors out of one sheet of 24X48 pine board from HD. Cut it down to size and routered the ends.
Everything except for the exterior paint job was from HomeDepot.
It took 15 days from buying the first 2X4 till the final coat of paint dried -- but I didn't work on it everyday.
By far the hardest thing to do was make sure the stand was level and plum while building the frame. I quickly discovered that my garage floor was not level so I moved the building to the saw horses which I first leveled with shims. If you don't keep all your corners square, you will not be happy with how the outer skin will fit and square up when it's added.
Here's a picture of me using pipe clamps trying to force it to square up while I add some more screws to it....
