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Tornado Shelter: Cutting the Lumber

The first step in constructing the shelter is to cut the lumber to the appropriate length and width.

111 of the 2x8s will make up the non-door walls and will need to be cut to be 91-1/2” long. The 22 remaining 2x8s will be cut to two shorter lengths (28-1/2” or 24”) in order to accommodate the door opening. 11 2x8s will also be rip-cut to modify their width. The ripped pieces will be used for the bottom and top courses of the wall to provide a flat surface at the slab and at the ceiling.

You Will Need

Materials Needed In This Section

  • 133 2x8 boards, 8 ft. (96") long

Tools Needed For This Section

  • Measuring Tape
  • Circular Saw
  • Sawhorses
  • Woodworking Clamps

Before You Begin

Inspect the lumber for warp and twist. Excessively warped and twisted boards should be set aside.

Note

Rip cutting lumber is more easily accomplished using a table saw. However rip cutting with a hand-held circular saw is an option.

Watch the Video

The first minute of the video is for Step 1 - Cutting the Lumber and Step 2 - Constructing the Beams. After 00:01.05 the video covers Step 3 - Assembling the Walls.

Written Instructions

Click on each image below, in order, for specific instructions.

Rip cut and cross cut lines (91-1/2" boards) Ⓐ Rip cut 11 boards to a width of 5-3/4”. Then cross cut each of these 2x8s to a length of 91-1/2”. These boards will be used as the inner board of three of the bottom beams, and the two outer boards of the four top beams in the shelter’s walls.
Cross cut line (91-1/2" boards) Ⓑ Next, cross cut an additional 100 boards to a length of 91-1/2” Width is 7-1/4”
Cross cut lines (28-1/2" boards) Ⓒ Cross cut 11 2x8s into three sections measuring 28-1/2” long.
Cross cut lines (24" boards) Ⓓ Next, cross cut 11 2x8s into three sections measuring 24” long.
Rip cut lines (24" and 28-1/2" boards) Finally, select one Ⓔ 28-1/2” long segment and one Ⓕ 24” long segment. Rip cut each of these shorter segments to a width of 5-3/4”.
Final Board Dimensions and Quantity - 11 pieces Ⓐ, 2” x 5-3/4” x 91-1/2” - 100 pieces Ⓑ, 2” x 8” x 91-1/2” - 32 pieces Ⓒ, 2” x 8” x 28-1/2” - 1 piece Ⓔ, 2” x 5-3/4” x 28-1/2” - 32 pieces Ⓓ, 2” x 8” x 24” - 1 piece Ⓕ, 2” x 5-3/4” x 24”

Step By Step Instructions

Last updated December 3, 2025
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