- 1). Tape two or more rolls of shelf paper together until you have an area equal to the sheet of plywood (4'x8') and lay it out flat on a large flat surface. Using the T-square, tape measure and pencil, create a template for the pieces you will be cutting out of the plywood to make a casket for Halloween decorating.
- 2). Draw the following on the shelf paper: three squares that are 12 inches by 12 inches, one square 8 inches by 12 inches and two rectangles 12 inches by 60 inches. Draw the bottom, also called the nailer (the lid is cut from the same template), by making a 12-inch line for the top of the coffin. Measure down 60 inches and draw an 8-inch line perpendicular to the top line and centered with it. Use the T-square to create sides of the base. The diagonals at the top of the coffin base should be 12 inches long and meet the 60-inch diagonals coming up from the bottom. Think toe-pincher casket. The top where the shoulders would be is wider than the bottom where the feet rest.
- 3). Cut out the template pieces and lay them on the plywood. Keep in mind you will need two of the largest pieces, one for the bottom of the coffin and one for the lid.You will need to use two sheets of plywood for this project. Trace the pieces onto the plywood and cut out with a circular saw. Keep the leftover plywood for additional Halloween decorations.
- 4). Place the bottom of the coffin on a flat surface and glue the three 12-inch by 12-inch squares in place. One will go at the head of the coffin to form the top, and the other two will form the short sides where the head would be in the casket. Apply a line of glue along the corresponding angles on the bottom, or "nailer" part of the casket, then place the squares in position and apply C-Clamps while the glue dries. Position the two side panels (the 12" x 60" rectangles) apply glue to corresponding angles on the nailer and attach the C-clamps until the glue dries.
- 5). Finish the base by gluing the 8-inch by 12-inch square in place at the bottom of the casket and sinking wood screws to hold all the sides in place. Fill the holes with wood plugs or wood filler. If you use filler, let it dry and sand it down.
- 6). Sand the Halloween coffin until the edges are smooth. Also sand the piece you will use as the lid. When you are done sanding, apply the wood finish or paint and let dry.
- 7). Set the coffin lid in place on top of the base and attach the piano hinge with the accompanying screws
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