All wood structure is standard wood strapping, 2-1/2" x 3/4". To fasten the wood joints, I used construction glue and 2-1/4" air gun nails to hold in place, then laid piece on concrete floor and applied small "gang nail strips" as you can see in the pics. I used 4 standard hinges to attache the sections together. To mount the removable top and front cross braces, I took a piece of 1-1/4" pipe about 2.5" long, split it in two, took one half, secured in the vise to bend the sides out a bit, then notched the center down about 2 inches, then drilled some screw holes on each side, grind the edges smooth, then screwed these mounts into position. On the brace ends, I just used 2" deck screw and left the head of the screw out a bit so that it slides into the notch of the galvanized mounts.
For the tarp, I used an electric solder gun with the plastic cutting attachment to cut/melt the tarp to shape, then wrapped onto the wood strapping and stapled with 3/4" crown staples from air gun on low pressure (approx 60 psi). Don't forget to allow extra tarp for the folding of the sides. Then cut the top tarp to size, sewed a loop onto the bottom front to insert a piece of strapping (see pic). Installed grommets onto the sides of the tarp in proper locations, installed bungee cords using clothes line crimps. Install top tarp and permanently screw onto the back. Install screws on the side frame to hook the bungee cord onto.
Happy Grilling.
