This step by step diy woodworking project is about a cat tunnel plans. This is PART 2 of the large catio project, where I show you how to build the simple 24″x24 tunnel. Remember that this is an example, but you can change the dimensions and shape of the tunnel to suit your needs. Take a look over the rest of our woodworking plans, if you want to get more building inspiration.
When buying the lumber, you should select the planks with great care, making sure they are straight and without any visible flaws (cracks, knots, twists, decay). Investing in cedar or other weather resistant lumber is a good idea, as it will pay off on the long run. Use a spirit level to plumb and align the components, before inserting the galvanized screws, otherwise the project won’t have a symmetrical look. If you have all the materials and tools required for the project, you could get the job done in about a day.
Projects made from these plans
Cat Tunnel Plans
- A – 2 pieces of 2×4 lumber – 120″ long, 3 pieces – 21″ long, 2 pieces – 96″ long BASE
- B – 2 pieces of 3/4″ plywood – 24″x96″ long, 1 piece – 24″x24″ long FLOOR
- C – 4 pieces of 2×2 lumber – 120″ long, 14 pieces – 21″ long FRAME
- D – 4 pieces of 2×2 lumber – 96″ long, 9 pieces – 21″ long FRAME
How to build a catio tunnels
The first step of the project is to build the floor frame for the tunnel. Use pressure treated 2x4s and assemble the frame, as shown in the diagram. Drill pilot holes through the side pieces and insert 3 1/2″ screws into the perpendicular components.
Use 3/4″ plywood for the floor of the tunnel. Align the edges flush, drill pilot holes and insert 1 5/8″ screws every 8″ along the framing.
Use 2×2 lumber for the side frames. Drill pilot holes through the plates and insert 3 1/2″ screws into the studs. Make sure the edges are flush and check if the corners are square.
Fit the side frames to the floor of the tunnel and align the edges flush. Plumb the wall frames, drill pilot holes through the bottom plates and insert 3 1/2″ screws.
Next, fit the other blockings between the side frames. Drill pocket holes at both ends of the supports and secure them to the sides with 2 1/2″ screws. Make sure the corners are square.
Next, we need to build the other tunnel. Use 1 5/8″ screws to secure the 3/4″ plywood floor to skids. Align the edges flush.
Build the side frames for the tunnel B. Drill pilot holes through the plates and insert 3 1/2″ screws into the studs. Make sure the corners are square and align the edges flush.
Fit the frames to the sides of the floor. Align the edges flush and plumb them with a spirit level. Drill pilot holes and insert 3 1/2″ screws to lock the frames into place tightly.
Fit the top supports to the cat tunnel. Drill pocket holes at both ends of the supports and insert 2 1/2″ screws to lock them into place tightly.
Fit the tunnel to the 8×10 catio and lock it to the frame with 2 1/2″ screws.
Assemble the tunnels together and lock them with 2 1/2″ screws. Staple wire mesh to the exterior of the cat tunnels.
Last but not least, take care of the finishing touches. Therefore, smooth the edges and make sure there are no wire exposed to injure your pets. Apply a few coats of paint / stain to enhance the look of the catio and to protect the components from the elements.
Make sure you take a look over the rest of my cat project plans HERE. I have tons of designs covering everything you need to keep you cat healthy and happy: insulated cat houses, window catio, large catio and cat trees. If you like my approach to designing woodworking plans, make sure you check out the list of all my free designs HERE.
In addition, if you want to build a 8×10 catio, check out PART 1 of the project. These 2 projects together make for the ideal cat shelter.
This woodworking project was about 8×10 catio plans free. If you want to see more outdoor plans, check out the rest of our step by step projects and follow the instructions to obtain a professional result.