Tron Legacy - Update 05/03/2016 - Mala Woes

[Woodshop Flunky]

method recommended by Bender looks interesting and it would mean buying another new tool. 

I'll try another sample using a sharp chisel before I decide which way to go.

As a side-note my wife and daughter think I am being way too anal about the T-molding fit.   

just an update, the last few times I did this I just removed the specialty blade that is inside the trimmer and used that by itself one side at a time (and you can buy just the replacement blades)

I trimmed the t-molding on my build and it turned out great with a very crisp edge.  I started out using a sharp chisel, but finally decided to use a razor box cutter.  The razor worked much better, and was very easy to work without scratching the laminate or my artwork.  One thing I noticed, when I was moving at a good speed, the razor would tend to climb up off the side.  After I trimmed, I would run my hand back over the edge and feel for any high spots... there were quite a few.  Whenever I found one, I'd just go over it again with the razor and  remove the high spot. http://forum.arcadecontrols.com/index.php?topic=111377.msg1203138#msg1203138

[wp34]

I trimmed the t-molding on my build and it turned out great with a very crisp edge.  I started out using a sharp chisel, but finally decided to use a razor box cutter.  The razor worked much better, and was very easy to work without scratching the laminate or my artwork.  One thing I noticed, when I was moving at a good speed, the razor would tend to climb up off the side.  After I trimmed, I would run my hand back over the edge and feel for any high spots... there were quite a few.  Whenever I found one, I'd just go over it again with the razor and  remove the high spot.

Thanks for the tip.     

I'm getting ready to glue the battens on mine and like you am a little nervous about not having wood on wood.  I'd like to do something similar to what you did.

I love how your cabinet turned out BTW.  That artwork is awesome.

[BobA]

There is a trimming tool you can use on t molding.  It is made for edge banding but it does the same thing for both.  Trim tool

[Bender]

This totally looks like a badass owl right now.  

I contemplated using laminate on my build and am very appreciative for the process feedback and refinement that you have provided.  Your results are outstanding but you're going to need to grow wings to make your deadline, can't wait to see it come together!

Thanks Le Chuck.  I'm really enjoying reading through your build.

just an update, the last few times I did this I just removed the specialty blade that is inside the trimmer and used that by itself one side at a time (and you can buy just the replacement blades)

Thanks for the update Bender.   I take it you are using the blades alone.  Are you using anything to hold the blade as you cut?

BobA's talkin bout the same thing

I just holding the blade in my hand
The cool thing is that there is only a small area this is actually a blade so it's next to impossible to mess up the laminate or artwork

click to go to woodcraft

[wp34]

Thanks BobA and Bender.  Merry Christmas!

[Woodshop Flunky]

I love how your cabinet turned out BTW.

Thanks! 

[wp34]

Not much progress over the holidays.  A lot of time off work but not much real "free" time.   I did get a chance to position the D9800 on one of my templates to take measurements for the supports.





Man that thing is heavy.  Not looking forward to trying to get it mounted.

[wp34]

Also when I bought the monitor it came with a bent support bracket.   When I contacted X-Gaming they wanted me to ship the whole monitor back instead of just sending me a new bracket.  I decided to just keep the monitor but haven't gotten around to straightening it yet.

[Hoopz]

Is that bracket one you can replace with something off the shelf at a big box hardware store?  Angle iron or anything like that?

[Green Giant]

Is that bracket one you can replace with something off the shelf at a big box hardware store?  Angle iron or anything like that?

No need.  That stuff doesn't look that thick.

Grab a big ass wrench, grab that metal, and torque that bad boy into place.

[wp34]

Is that bracket one you can replace with something off the shelf at a big box hardware store?  Angle iron or anything like that?

Good idea but it is an odd shaped bracket with an angle on each end.

[wp34]

No need.  That stuff doesn't look that thick.

Grab a big ass wrench, grab that metal, and torque that bad boy into place.

You are right it isn't that thick but that monitor is a member of an endangered species.  Gotta treat it with kid gloves.   

[Green Giant]

No need.  That stuff doesn't look that thick.

Grab a big ass wrench, grab that metal, and torque that bad boy into place.

You are right it isn't that thick but that monitor is a member of an endangered species.  Gotta treat it with kid gloves.  

I have heard stories about those old monitors bouncing off concrete.  I don't thing a little bending on a piece a metal will hurt anything.

Just channel this guy when bending:

[Nephasth]

Grab a big ass wrench, grab that metal, and torque that bad boy into place.

Definitely the easiest solution. My first pick would be a crescent wrench, second pick would be a pair of channel lock pliers.

[Hoopz]

Is that bracket one you can replace with something off the shelf at a big box hardware store?  Angle iron or anything like that?

Good idea but it is an odd shaped bracket with an angle on each end.

Shoot, this isn't a set back.  It's a chance to improve your skills and, in turn, better support your family.  Looks like you'll need some new tools to cut through metal, weld, etc.  The tools you'll be buying are an investment and should not be factored in to the cost of this project.

And what FE are you going to be running?  GameEx has a Tron theme that's pretty nice.

[SammyWI]

Grab a big ass wrench, grab that metal, and torque that bad boy into place.

Definitely the easiest solution. My first pick would be a crescent wrench, second pick would be a pair of channel lock pliers.

I would recommend removing the bracket from the monitor when you straighten it.   

[wp34]

And what FE are you going to be running?  GameEx has a Tron theme that's pretty nice.

Oddly enough I've never looked at GameEx in all these years.  I took a look at the Tron theme and I like it.  I've been using Mala but am not real happy with it so I'll give GameEx a try.  Thanks for the tip.   

[wp34]

Been slow going lately but I did get some time to get the base done. 

Here is is clamped and glued.


All Done.  Once I flipped it over I saw that I didn't get the holes drilled perfectly straight so the bolts don't line up.  Oh well.  I'm the only one that will notice.

[wp34]

I test fit it on one of the sides.  Looks great.



I took the base home from the shop to test it for level.  The kids are taking turns riding on it.

Built to Shred!

[BadMouth]

 
What's the holdup?
Get back on it!

[wp34]

What's the holdup?
Get back on it!

I've been out of town and we have been busy with kids stuff.  You know the drill.

I actually made some progress right before my trip but have not had time to post.  I'll try to get something up this weekend.

[wp34]

I decided to route out the cut-outs for the battons similar to Woodshop Flunky, Martijn and others.

Instead of making a full template I decided to make one jig I could use for each batton.  The cutouts don't need to be absolutely perfect as they will be either covered by the front/back panels or on the inside of the cabinet.  I used a piece 1/4 pine and cut out the inside using a table saw.  The lip is about 7/8" as I'm going to want my battons to be 1" in from the lip.  I just line up the lip of the jig with the edge of the side piece and clamp.  I used a scrap piece from the jig when I need to adjust the size of the cutout.



Now the fun part.



Later I went back with a chisel and smoothed out the rough edges. 

[wp34]

I set the two side panels side-by-side on tables and just went back and forth.  Only screwed up once but that will be hidden. 

Like others I frequently use my laptop in the shop.  I get a kick out of the juxtaposition of old and new technologies.  Here I am sneaking a peak at Gamester's thread again.   



I made a jig to ensure that the battons are 1" from the lip.

[wp34]

I pre-drilled some holes thinking I might drill back from the outside to ensure the battons are secure.



Line up the batton with my jig leaving a 1" gap.  After the side panels are installed this will leave me with a consistent 3/8" reveal.



Glue and screw.

[wp34]

Rinse and repeat.



Can you see where I messed up?     One of these things is not like the other...

[wp34]

My brother-in-law is a professional carpenter.  I asked him to come help me cut the angles on the side panels as I had a number of precise cuts to make.  He worked for a company that specialized in laminating for a while and he showed me a different and somewhat easier way to laminate.  I had not seen this before and thought I should document it here.

First off he uses a can of Loctite as glue so no rolling.  He also cuts the panels to a rough size before laminating.  We laminated and then cut the laminated pieces to the final size.  It seems bass-ackward but really went amazingly quick.



You spray an even coat on each piece.  Spray the glue up and down on one piece and side-to-side on the other.



You should end up with a spider-web looking mess of glue. 



His process seemed to go much faster than the way I was laminating.  For one thing the roll-on glue I was using would get soaked up by the MDF requiring multiple coats.  The spray does not.  The spray also tacks up much faster. 

[wp34]

Here are a few photos that show how we measured the angle cuts for the panels and set up the saw.

Measure the angle with a compass.



Cut some test pieces at that angle using the miter saw.



Test fit.



Use the test pieces as a jig to set the angle on the table saw.

[wp34]

The panels are laminated and cut at this point.  Now I need to cut holes for vents and the coin door.

I used a hole saw to rough cut the vent.



Used a flange as a template to route the hole to size--another idea from Gamester.   


I found a PVC vent at Menards for $1.00 that will work nicely as a vent cover.

[wp34]

Test fitting the coin door.  I've been waiting to see this for a long time.   



Just need to cut the back door and make holes for the speakers then it is time to put it together.  I couldn't resist lining all the pieces up.  It looks like I ordered a kit.

[PIZZ]

PCV vent cover, nice idea. im going to have to steal that from you 

[dandare]

Does look like you just had a pro kit delivered.

This is looking great man, look forward to seeing more! 

[wp34]

Thanks PIZZ and dandare.

[wp34]

Got a little careless on the table saw last night.  Really stupid on my part.  I was trying to use it like a miter saw and the 2x4 got away from me.

Two stitches and a tetanus shot later... 

Take a look at my middle finger.  The blade cut a "v" in my fingernail.



Here is one of the gloves I was wearing.  Ouch.

[Le Chuck]

Glad you still have all your digits.  Take care man. 

[SammyWI]

Cab is coming along nicely.  Hope you heal up fast so you can back at it.

[wp34]

Thanks guys.  Should be back at it in a couple of days.

[Hoopz]

Glad you're ok.  Wife get mad at you once she knew you were ok?

[wp34]

Glad you're ok.  Wife get mad at you once she knew you were ok?

Thanks Hoopz.

Funny.  Somebody at work just asked me that a few minutes ago.  She really didn't.  No "I told you so's" either.  But I made it really clear from the get-go that I screwed up.

The doctor told me I should have gone to the emergency room.  I think she felt bad after the fact that she didn't make me go. Neither one of us thought it could be stitched though.  Lesson learned.

I think if my dad were alive I might have heard a little about it being that it was his saw.  I knew better and was just in a hurry.

[Le Chuck]

I watched my sculpture prof in college saw his index finger in half longways to the first knuckle.  Not a whole lot you can do for that one because of the waste.  He was teaching a safety class, it can happen to anybody.  Just be glad you didn't shoot yourself or anything too traumatic. 

[bigmatty77]

I watched my sculpture prof in college saw his index finger in half longways to the first knuckle.

Ouch! 

wp34, glad you're ok man. Glad it was only a couple of stitches and nothing worse.  Just wanted to say you're cab is looking amazing so far, very proffesional. Starting wish i'd gone laminate now