How we build Lil Boulder Kids Climbing Walls

MATERIALS

  • 1 x 3/4in ACX pine plywood (sanded on one side) – 8 x 4ft sheet
    • Get plywood cut into two 4ft x 4ft panels
  • 72 x 3/8th in zinc plated t nuts with 16 thread pitch 
  • 25 x Rocky Mountain bolt-on climbing holds 
  • 25 x 1.75 in bolts, 3/8th diameter (for bolt-on holds) 
  • 1 x 7/8th spaded wood drill bit (MP to confirm if 7/8th or 7/16th) 
  • Paint primer
  • Paint
  • Varnish
TOOLS & EQUIPMENT
  • Paint & varnish rollers 
  • Drill
  • Hammer
  • Painting tape 
  • Sand paper or sander

BUILD PROCESS

  1. Start with two 4ft x 4ft plywood panels. Lay them down with the sanded side facing up. Ensure they came from the same 8ft x 4ft sheet and the cut edge matches up perfectly.
  2. Using the 7/8th spaded wood drill bit, drill a 6 x 6 grid of holes in each piece of plywood (36 total). Be sure to start drilling on the sanded side of the board.
  3. When one board is flipped, and placed on top of the other, a wall with an even grid of 72 holes is formed:  
  4. Sand around the holes on the face up side (pre-sanded side) to ensure it’s smooth. Clean up any chips or sharp edges on the backside of the plywood. 
  5. Flip the plywood panels over so that the sanded side is facing down. Add superglue to T-nuts and hammer in a T-nut into each hole (72 total). Be sure to hammer them in straight and until they are flush against the board. 
  6. Flip each plywood panel back over so the sanded side is face up (t-nut side face down). Lay out the plywood as displayed in step 3. 
  7. Apply white primer to the sanded side of both boards as well as the 3/4in rim around the board. Apply 2 coats to each board (or more if required). The goal is to have a solid white surface, without any original wood colour or pattern showing.
  8. Wait to dry.
  9. Use painter’s tape to create a mountain design, then roll on paint. Apply 2-3 coats per colour (until each colour looks even). Ensure the rim around the board is painted as well.
  10. Using a clean foam roller, apply thin coats of varnish to the entire wall. Use a consistent and down pattern to avoid brush marks. Diligently roll out any bubbles. Apply three coats.
  11. Let the wall sit and dry for 48 hours.
  12. Cut planks of 2x4 lumber to create a frame for the wall. Make sure to use additional pieces to support the interior as well, ensuring that the framing does not cover any of the 72 holes.
  13. Lay out the frame, and place the wall panels on top.
  14. Fasten the panels to the frame by using flat head wood screws.
  15. Install, following the installation guide here.