Phetishboy
Well-known member
So I got commissioned to build a shadow box for a Kong-off marquee. I thought to myself: "build a box with four sides, paint it, add four pieces of aluminum framing, throw in a light fixture, done." Well, as I started the project, for some reason, I felt inclined to step up the design. I started by taking a 3 foot piece of 1x6" lumber and clamping it to the top of my Punchout! cab. I used an end bearing trim bit on my router and copied the top curve of the cabinet. Flipped the board, re-clamped, cut the other curve. Cut the back straight, then used this piece as a pattern for the other side piece. Sanded, bondoed, primed, painted each piece. Cut T-molding channels into the front, top and bottom edges of each side piece. Cut 2 cross pieces to length, routed the back edge 1/4 for an inset backer board. Sanded, primed and painted these pieces black. Cut 2 short 1x1" square dowel pieces to attach all four pieces together. Glued and stapled the box together. Cut a piece of 1/4" pegboard for the back of the box, primed and painted one side black. Installed the light fixture to the bottom, fabricated a switch mounting plate (out of an old Midway leg leveler plate) installed the plate and switch to the top and wired them both up. Cut and added heat shrink tubing to the front of the terminals to prevent shocks. Cut two pieces of aluminum angle to length. Measured and drilled 3 holes per piece for attaching angle pieces to the box. Deburred both pieces. Primed with an aluminum primer, painted both satin black. Grabbed a DK marquee for test fitting. Lit it up. I am still waiting on blue vinyl and one other surprise to show up, then I will install the special 3/4" white T-molding I bought. After those 3 items, this piece will be ready to ship. Pics so far:
