First Commissioned WW Project

[bigsteel15]

WOOHOO!!
I'm almost embarrassed to tell what it is, but I got my first commission today.
Not exactly fine WW but one of my bosses (3) came to me today and said he needed 4 outrigger pads made for our portable crane. He asked could I contact the guys we use for making crates, shipping supports, etc.

Robin (boss): "I would get the guys in the shop to do it but we are short staffed already and I'll probably get crap for wasting valuable time"
Brian: "What do they look like?"
Robin: "Just 30-36" square x 4-6" thick wood blocks with a rope handle attached to each end"
Brian: "I can make those"
Robin: "Really?"
Brian: "Sure, no problem, just pay for the materials and a little something for my time."
Robin: "OK let us know how much"

Brian then proceeds (after smacking himself upside the head) to go out after work and purchase said materials:
(18) 2x6 x 12 ft
(2) sheets 3/4" cheap plywood
40 ft 3/4" OD poly rope
Total: $210.00

Started cutting up pieces (just under 32" long so as to fit 3 on a 96" sheet of plywood)
2x6 pieces, 6 wide, cross next layer, screw together, cross next layer, screw together, sandwich this stack between layers of plywood and screw together...WAY too many screws.
I think this will warrant rental of a framing nailer this weekend.

I won't get to use a lot of tools: CMS, CS, Router.

Sorry this is so long, but I do have questions:
How much does Gorilla glue expand? I'm thinking of using it to fasten the rope in a 3/4" groove sandwiched between 2 layers of 2x6.
Do you think it will hold, or will the glue melt the rope? the other option is to tie a knot in the rope and make a large receiving area for the knot at the end of the groove.

[bigsteel15]

So I asked Robin today if the Poly rope was OK. NOPE!!
He asked me to use nylon. Apparently poly doesn't do well outside over the long term.
Nylon is 2-1/2X the price, but oh well, not my money.

So back to my question about Gorilla glue for holding the rope.
Will it work, or destroy the nylon rope?

[RayintheUK]

I wouldn't rely on any type of glue in the circumstances you describe, Brian. Knotted ends will be much more secure.

Ray.

[LarryG]

I won't get to use a lot of tools: CMS, CS, Router.

BRRRRRRTTTT! Hey, thanks for playing, but if you can build a project without finding an excuse to buy a new tool, you're automatically disqualified, with a mandatory six week suspension.

[bigsteel15]

So thinks you

BRRRRRRTTTT! Hey, thanks for playing, but if you can build a project without finding an excuse to buy a new tool, you're automatically disqualified, with a mandatory six week suspension.

Actually, see this post.
http://www.bt3central.com/showthread.php?t=22502

My existing CMS is a $100 POS and I've been looking for an excuse to upgrade.
Either that or HD has a framing nailer on clearance that I'm going to look at right now. Now there's something I'd buy and maybe never use again.
TAKE THAT Larry!!