5: Post Shaping/ Cutouts

Cutting the post to shape is a bit tricky. I used a circular saw, hand saw, and a belt sander (highly recommended for this! I used a Black & Decker Dragster.)

The plans also note: there should be no sharp edges, so make sure to thoroughly sand.

First measure the primary point. Since the post is so thick, I could only cut through partially with my circular saw to start.

Then, I flipped it over and cut through again. Since they didn't align perfectly, I used a belt sander to make the edges flat.

When I finished that, I marked the top to make it perfectly square and sanded it down.

The weight of the box will hang directly on this point, so it's important that this is square.

Next, I marked up the first cut-out and cut it out with a hand saw. Note that the post is rotated 90 degrees for this cut-out:

Finished cut-out, sharp edges sanded smooth.

To assist tiny claws to grip, I roughed up some ridges for them (see note on using a framing hammer for roughing-up surface later.)

Next, measure and cut out the second cut-out, on the opposite side.

Finished second cut-out:

For the next step, lower the completed main box onto the post and mark where the bottom of the box reaches.

This will allow you to measure the positions of the spacer blocks correctly.

I wrote the position on the post, so when the box is in place, I know where to put in the screws.

Attach the first spacer block as measured, then measure a location of the second spacer block:

Attach the second standoff block:

Finally, I used a framing hammer (it has a spiky waffle-iron looking head on it, which I found perfect) to rough up the wood,

to ensure that the bats can get a grip:

Finished post: