You should now have all the boards cut and ready to make six side panels including a head panel (16x18), a toe panel (12x18), two long (toe) side panels (56.375x18), and two short (head) side panels (24.375x18). We will attach a 1x2 to the bottom edge of all size side panels. This member will serve as the floor support for the casket transferring the weight on the floor to the sides of the casket in a shear plane (vs. a tension joint) adding strength of the coffin. These rails need not extend all the way to the outside edges of each side panel--each rail should be 1-2 inches short at each end to leave clearance room for the vertical ribs on the adjacent side panel. Particularly at the middle joint between the head (short) and toe (long) panels you will want to leave at least 2 inches to make room for the 4-inch joiner rib.

5) Assemble the Side Panels and Lid

Starting with the lid, fasten together the long boards that make up the lid with 2-inch ribs and glue. Use 4 ribs to assemble the lid placing one rib 1-inch from the head and toe ends of the lid and the remaining 2 ribs evenly spaced in between. Use glue and screws to secure the ribs. If preferred, you can remove the screws from the ribs after the glue dries--let the glue cure for 24 hours before removing the screws.

In a similar fashion, assemble the 6 panels that make up the sides, head, and foot of the coffin using ribs, glue, and screws. The following are some tips to follow while constructing the side panels.

Try to use the same board for both lower head and toe boards and upper head and toe boards on side panels so that the same board widths and wood grain match at the elbow where the coffin bends.

When you attach ribs to the side panels, carefully position the ribs at the far ends (to leave room for the head and foot panels) back from the edge the same distance as the thickness of your boards (about 3/4 of an inch). Use a piece of scrap as a spacer while you attach the ribs.

Leave room between the lower end of each rib and the floor frame rails for the floor boards to fit. Unless you intend to run the boards through a joiner-planer for a perfect smooth edge, there is no need to glue the edge of the top and bottom boards for the side and end panels. The ribs will provide enough strength without edge gluing the side panels. If you use screws and glue to join the ribs, you can remove the screws after the glue dries--after about 24 hours.

6) Assemble the Floor and Sides

The next few steps will require some patience. A few extra hands will serve well. Starting at the narrowest part of the coffin at the toe-end of the long (lower) side panels, secure the toe panel to both of the sides of the coffin. Next we will cut a special floor board that will join the toe end of the coffin with the head end. First cut a board exactly 24 inches long. Then from the middle of each end cut angles using approximately 6 degrees for the toe angles and 10 degrees for the head angles. The longest part of the board from end to end should still be 24 inches. Position this board where the toe and head ends of the coffin will join together and fix into place with glue and screws or nails. This floor board along with the joiner ribs will secure the head end and toe ends of the casket together.