I grabbed two 3/4" Birch Plywood from Lowes for $39.95 each (no sales tax here)
.
Here is the first side cut out:
After getting the first side to where I wanted it, I placed it on a new sheet of 3/4 Ply and traced it.
Then I rough cut that outline, clamped them together and flushed trim the second piece.
Odd Whale or Airplane shape when side by side
I recieved my 3/4" Samples from
T-Molding.Com, I decided to go with the Light Blue.
And of course my first
U360 from Ultimarc.comSo running cost so far:
2 3/4 Birch Plywood: $39.95 x 2 = $79.90
T-Molding Samples: FREE + Shipping = $1.22
U360 Joystick: $59.00 + $14.00 Shipping = $79.00
Total Project: $160.12
------------------------------------------------------------------------------------------------------
Using a Test Piece and centering the bit, I routed out a slot for the T-Molding.
Using the 5 Ply Plywood it was a no brainer, I aligned the bit on the 3rd layer then micro adjusted my router depth so it was perfect.
To be sure it would be completely centered I first Slotted one side then flipped the piece over slotted it again.
It is perfectly centered now, however I found the 3/4" Trim in the 3/4" Ply left the T-Mold proud by 1/16th on each side.
Now at first I was going to Paint the cab but after all the advice here I decided to laminate the cab.
My guess (Hope) is the Laminate I saw at Home Depot will be 1/16ths and all will be well...
Here is the
Bit at Amazon.Com that I used to make the Slot, you will need this
Shank if you dont already have one.
Cost
Shank: $7.07
Slot Bit: $12.00
Shipping: $4.80
Total: $23.87
Project Total: $183.99
--------------------------------------------------------------------------------------------------------
Next I worked on my base, I went to Lowes and bought two 2" Swivel and two 2" Fixed Casters.
I decided I did not want the Screws coming up through the bottom of my cab.
I came up with a solution, I would just use my Forstener bit to counter sink the Hex Bolt and Washer then use a Lock Washer and nut on the bottom supports then affix the Cab Bottom piece ontop of that. Still would be a piece of cake to change out a caster if I ever had too.
Bottom Supports with Wheels Installed:
Counter Sunk Hex Bolts and Washers:
2 Inch Clearance from the sides so the wheel will swivel:
Originally the base would be part of a adjustable shelving unit.
Then I got to thinking maybe it would be cool if the Door was actually a full extension Drawer.
So that is where I am for now, not sure if I want to use a Heavy Duty full Extension slide for a drawer front.
Cost
4 Casters: 4 x 3.98 = $15.92
Project Total: $199.91