How to Make a Small Metal Quarter Pipe

Cut the 2x4s into 11 pieces measuring 47.5 inches long.

Use the chalk line to draw the shape of the ramp's sides on the 3/4-inch sheet of plywood. The transition panel should measure 2 feet tall by 5-feet 1-1/4 inch long at the bottom. From the top point of the panel, draw a straight line measuring 2 feet, then draw a curved line with a radius of 5 feet 6 inches down to the end point of the base. Draw two identical transition panels. Draw a rectangle measuring 4 feet by 2 feet in the 3/4-inch plywood as well.

Use the jig saw to cut out the two transition panels and the rectangle you drew on the 3/4-inch plywood. After you cut the first transition panel, you can lay it on the other drawing to help guide the saw (these panels need to be identical).

Stand the first transition panel, then attach the first 2x4 (oriented with the 2-inch side running parallel to the ground) to the bottom right angle of the panel). Use two screws to fasten the board in position, insert the screw through the panel first, then into the end of the 2x4. Attach a second 2x4 (oriented in the same manner as the first) into the top, right angle of the ramp; this board will run parallel to the first 2x4. Use two screws to fasten this board in the same manner as the first. Attach these two 2x4s to the second transition panel so that it mirrors their position on the initial transition panel.

Attach another 2x4 at the top edge of the curved radius (the transition) of the ramp. The 2-inch edge of the board should run parallel with the ground). Attach it two both transition panels with two screws at each end.

Attach a 2x4 at the top of the curving edge with the 4-inch side of the board running flush with the edge of the plywood. Use two screws to fasten it to the transition panels at either end. Attach another 2x4 at the bottom of the curving edge of the transition with the 4-inch side of the board flush with the curving edge of the transition panels. Fasten the board with two screws at either end.

Connect the remaining 2x4s in increments of 8 inches along the top edge of the ramp. Place two more 2x4s between the two boards you installed at the top (flat part) of the ramp, then install others along the transition edge of the panels. All of these boards should be oriented with the 2-inch side flush with the edge of the plywood. Fasten the boards with two screws at each end.

Drill a 3/8-inch hole through the steel pipe about 3 inches from either end, then drill another hole directly opposite to the two holes with a 3/16-inch drill bit. The 3/8-inch hole will allow you to insert a screw through the 3/16-inch hole and into the wooden frame of the ramp. Lay the rail along the top of the transition, then connect it with two screws -- one at each end.

Lay the 4-foot by 2-foot section of 3/4-inch plywood on the top, flat face of the ramp. Insert a screw through the plywood to attach it to each underlying 2x4, space the screws about 1 foot apart along the 2x4s.

Cut a section of 3/8-inch plywood measuring 3-feet 9-inches by 4-feet. Lay this rectangle of plywood on the face of the transition to cover the entire curving section of the ramp. Insert a screw in foot increments along each of the underlying 2x4s underneath.

Lay the 4-foot by 4-foot and 1-inch remaining section of 3/8-inch plywood on the transition of the ramp. Push the longer edge of the rectangle against the metal pipe at the top of the transition, then attach the plywood with screws in foot-long intervals along each of the underlying 2x4s.

Drill 3/16-inch holes every 8 inches along the perimeter of the sheet metal, then lay the sheet metal over the entire transitional surface of the ramp. Insert a screw into each hole, then screw them down into the underlying wooden frame. Screw each one down until it is flush with the surface of the sheet metal.