A week ago I decided I was going to knock up a 1/2 size Pong cab.
The purpose of the build was to check the dimensions of the plans and work out any issues if they arise with the artwork and finishing of the cab.
The panels will be 9mm MDF for the fromt and 9mm plywood for the sides, adhesive vinyl was used for the woodgrain.
https://www.bunnings.com.au/boyle-1-5m-x-45cm-natural-dark-wood-self-adhesive-film_p1661110
The control panel was printed it onto gloss photo paper at home.
I've learnt that it's easier the make a template out of 18mm marine ply for the irregular shapes and flush trim each panel with the template using a router.
A complete side can be cut and shaped in a mater of seconds as opposed to hand cutting the profiles with a jigsaw (which never cuts perpendicular) and sanding into shape.
A fair amount of time and attention to detail is required for fabricating the templates but the amount of time saved when cutting multiple panels is definitely worth the effort.
The same was done for the bezel cutout.




Here's a short video of the flush cutting being done.
The blank panel was cut 3mm oversize.
I use the template to draw an image over the panel and rough cut the profile with a jigsaw.
The roughed out panel is laid over the top of the template and the bit is set so that he cutting edge is 1 or 2 mm longer than the panel you're cutting.
I square the bottom and back edges together with the template then clamp them together, I do a first trim to reduce the 3mm down by about 50%.
I then do a final pass in one straight run if possible.
https://youtu.be/AB5VaO7ek-0


The purpose of the build was to check the dimensions of the plans and work out any issues if they arise with the artwork and finishing of the cab.
The panels will be 9mm MDF for the fromt and 9mm plywood for the sides, adhesive vinyl was used for the woodgrain.
https://www.bunnings.com.au/boyle-1-5m-x-45cm-natural-dark-wood-self-adhesive-film_p1661110
The control panel was printed it onto gloss photo paper at home.
I've learnt that it's easier the make a template out of 18mm marine ply for the irregular shapes and flush trim each panel with the template using a router.
A complete side can be cut and shaped in a mater of seconds as opposed to hand cutting the profiles with a jigsaw (which never cuts perpendicular) and sanding into shape.
A fair amount of time and attention to detail is required for fabricating the templates but the amount of time saved when cutting multiple panels is definitely worth the effort.
The same was done for the bezel cutout.




Here's a short video of the flush cutting being done.
The blank panel was cut 3mm oversize.
I use the template to draw an image over the panel and rough cut the profile with a jigsaw.
The roughed out panel is laid over the top of the template and the bit is set so that he cutting edge is 1 or 2 mm longer than the panel you're cutting.
I square the bottom and back edges together with the template then clamp them together, I do a first trim to reduce the 3mm down by about 50%.
I then do a final pass in one straight run if possible.
https://youtu.be/AB5VaO7ek-0


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