Crossfit Plyo Box

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Project by Fchilly posted 04-26-2019 05:42 PM 1297 views 2 times favorited 5 comments Add to Favorites Watch

This is a version of the tabbed joint plyometric box commonly used in crossfit. I practiced drawing it up in fusion 360 to gain a little experience in drawing and sorting out mistakes using CAD prior to any actual cutting. Then I used a cut list optimizer to plan out plywood sheet cuts to limit scraps/excess, and then batched out 5 boxes.

The dimensions are 30” x 24” x 20”

-- Fchilly

5 comments so far

View Jerry's profile


3508 posts in 2990 days

#1 posted 04-26-2019 07:29 PM

Very nice. I recently had a discussion with one of my friends about these. The commercially available ones carry a very high price tag and are not anywhere as nice as this one! Great Work!

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be.

View robscastle's profile


8360 posts in 3546 days

#2 posted 04-27-2019 07:05 AM

Plyo Box ? ...had to go check it out looks very similar to my Ute boxes.

However I see its an exercize aid, ...much the same as mine as I haul them in and out of the Ute!

-- Regards Rob

View MrLaughingbrook's profile


289 posts in 3309 days

#3 posted 04-27-2019 11:36 AM

I like it. Please share with us how you cut the plywood to form the tabs.

-- MrLaughingbrook

View Fchilly's profile


50 posts in 1823 days

#4 posted 04-28-2019 06:27 AM

Thanks everyone, I forgot to mention there is an internal panel mortise and tenoned for span wise support.

How I cut the tabs… I cut out all the panel blanks first and with the scraps I made a replica of each joint of the box as accurately as possible with a band saw to use as a template. Once I successfully fit check the templates to each other I clamped them to my stock and routed out the part with a pattern bit. Once I made one of each side, I used that as my full size template. I used the same one over and over to prevent tolerance stack up. Also, prior to routing I drilled one 1/4” hole in each corner of each tab to help with fit. I used the same template idea for this, measure once and transfer all the rest.

I hope this all makes sense!

-- Fchilly

View Notw's profile


1180 posts in 3095 days

#5 posted 04-29-2019 02:42 PM

nice, rounding over the corners will do wonders to save shins, good job

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