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Author Topic: Mountain Jukebox version 2 Prototype Build  (Read 8078 times)

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mountain

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Mountain Jukebox version 2 Prototype Build
« on: May 18, 2013, 08:50:07 pm »

Standard black DIY kits available now.







Mountain Jukebox V2 Prototype project

Over the winter, I started planning a new version of the "Mountain Jukebox". I decided it was time to give the juke a face lift  This time, I get to keep the original  :cheers: 
I have kept the overall look the same, but have made it smaller. Anothe change is the monitor, I will be using a newer, wide format touchscreen with better specs. The plan is to apply techniques and tricks  learned in the 4 years since getting my feet wet with the CNC machine. I learned a lot making the original kits and have found ways to make them better and easier to produce in my tiny garage.  This winter gave me the opportunity to update and improve the CNC and develop fixtures to aid in producing repeatable, quality parts, fast. I also built an auto cycling vacuum pump press that will allow the top/sides piece to be one laminated piece. I will try to document some of the jigs and processes here as I work through them.

So first off is the mold needed for pressing the laminated top/side. It is built taller and wider than the final part to allow for trimming of the cured part to the correct size. With that said, the mold itself is still smaller than the original jukebox kits. This thing will be small. I wrapped it with a piece of plywood and smoothed it out. Since I plan on making the inside look as nice as the outside, I spent a lot of time getting it damn near perfect. The vacuum press clamps down with 1700 pounds per square foot of pressure at full capacity, so any imperfections in the mold will transfer to the final part.

Filled and smoothed







Primed













Here is the vaccum pump system built from a pump I found on eBay. After a rebuild kit, it runs like new and will pull and hold 26" of mercury (Hg). The kit parts were sourced from here. http://www.veneersupplies.com/categories/Vacuum__Press__Items/Vacuum__Press__Kits/









Here is a shot of a test run I did today without any glue.












My oldest is graduating this year so time is limited for the next month or so. Once I make the top and get it trimmed and sanded, I will begin working on the jig for the front and back parts.


stay tuned...
« Last Edit: October 29, 2013, 11:21:05 am by mountain »

Typefighter01

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #1 on: May 18, 2013, 09:21:08 pm »
How loud is your vacuum pump system and does it run until it reaches a certain (Hg) then shut off and hold its pressure, or does it constantly need to be running.

As AJ always likes to say "Subscribed"... ;)

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #2 on: May 18, 2013, 09:25:33 pm »
The pump is very quiet and runs until it reaches around 22 Hg. It held vacuum today for over two hours and it never needed to kick on. I read that every 15 minutes is acceptable. I must have done a good job connecting everything.

Bender

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #3 on: May 18, 2013, 10:55:40 pm »
What a joy it is to see your work  :cheers:
Can't wait to see this project throughout
Plus you have built the most wonderful toys!

Le Chuck

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #4 on: May 18, 2013, 11:07:44 pm »
I'm so jelly of the setup!  Can't wait to see more.

Termin8tor

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #5 on: May 19, 2013, 11:40:53 am »
Looking forward to this. I loved the first one.

orion

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #6 on: May 19, 2013, 05:49:03 pm »
You are like the Norm Abram of Juke Box builds... This is going to be fun to watch  :cheers:

Jigenjuke

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #7 on: May 19, 2013, 06:36:45 pm »
Great toys and Great Builds!

Jigenjuke

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #8 on: May 19, 2013, 09:18:14 pm »
^^ What Jigenjuke said!

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #9 on: June 01, 2013, 09:15:05 pm »
Thanks everyone!


I was able to get on this for a couple of hours last night and tonight, so I figured I would post some progress pictures. The bent panel is made up of 3 different pieces of plywood and 2 pieces of ribboned Sapele wood veneer. The core is a piece of 3/8" Bendy MDF, sandwiched by two pieces of 1/8 plywood. The Sapele veneer is on the inside and outside. These all add up to a total thickness of .65".


Here it is all clamped down.





The first two layers are wider in order to make trimming the part easier on the table saw. The black and clear mesh pieces are to allow the air to flow out evenly across the part to avoid air pockets.





Out of the bag prior to trimming.















The sides are trimmed and looking good. With so much time reading about this technique (and money) it's a relief to know that it works very well.











Next up is to make a jig for the table saw that will act like a sled and allow me to clamp the part down and square up the bottom. stay tuned...

« Last Edit: June 02, 2013, 08:51:20 am by mountain »

Rick

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #10 on: June 01, 2013, 09:50:52 pm »
Simply. Awesome. This is awe-inspiring. I can't tell you enough how amazing your work is!!!

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #11 on: June 02, 2013, 09:37:45 am »
Thanks Rick.


This is the inspiration for the look of the juke. One of my other hobbies is collecting and restoring vintage stereo gear. Specifically, late 60's to late 70's gear. I want to mimic the look by using the real wood veneer and an aluminum face, oh...and big ole shiny knob.



« Last Edit: June 02, 2013, 10:00:43 am by mountain »

yotsuya

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #12 on: June 02, 2013, 01:03:24 pm »
If you used needle-based VU meters, that would be the icing on the cake.
***Build what you dig, bro. Build what you dig.***

sabreerbasAlpha

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #13 on: June 02, 2013, 01:29:47 pm »
Well. I just sat and stared at that finish after the trimming. :censored:ME... And that vacuum technique OMG..!!!!!  :notworthy: :notworthy: :notworthy: :notworthy:

This is going to be so so good.

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #14 on: June 02, 2013, 05:10:21 pm »
If you used needle-based VU meters, that would be the icing on the cake.


I probably would if there was more room. I'm trying to keep it as small and compact as possible.

Ond

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #15 on: June 02, 2013, 08:28:43 pm »
Very nice to see someone around here using real timber veneer on a project, I think it just elevates the classiness to a whole nother level.  You are the second fellow here to use a vacuum system for shaping that I know of.
You might think that you're scared, but you're not.  That isn't fear.  That's your sharpness.  That's your power.

kahlid74

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #16 on: June 03, 2013, 09:55:36 am »
Looks great man, keep up the good work!  Love the vacuum system.

abispac

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #17 on: June 03, 2013, 01:17:37 pm »
Cant wait too see where this is heading... great job.

monkeychunkuk

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Mountain Jukebox version 2 Prototype Build
« Reply #18 on: June 03, 2013, 02:28:33 pm »
Its like watching the old Yankee workshop,using tools i haven't got to a standard i can only dream of,the standard is simply amazing cant wait to see the finished machine!



abispac

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #19 on: June 12, 2013, 04:20:04 pm »
no updates?

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #20 on: June 13, 2013, 10:18:53 am »
no updates?


Currently waiting on some materials. No real free time until next week anyway, but, I have been tinkering with ideas and designing parts in CAD. I hope to have something to share next week.

Superfrog

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #21 on: June 18, 2013, 05:01:08 pm »
  Love the vacuum system.

Is there something you wanna talk about  :laugh2: :laugh2:

Mountain,

Before I started posting here, I was following your amazing build and I love the nice details .... at the end, that's what it made a GREAT piece of work.

I am a MDF guy, but I like to see other build like yours and Ond who used all kind of wood.

What if you made your Jukebox with MDF, will it be lighter than your version?
Will this Jukebox version a 2.0 of the first one or completely different ?

Keep an eye on this one  :notworthy:
« Last Edit: June 18, 2013, 05:12:26 pm by Superfrog »

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #22 on: June 18, 2013, 07:11:40 pm »
The original was made from MDF. The new will be 100% made from cabinet grade plywood, which is way lighter than MDF.

This version will have the same basic shape, but will be smaller, lighter, and easier to build from a kit.

mcseforsale

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #23 on: June 19, 2013, 01:01:50 pm »
How loud is your vacuum pump system and does it run until it reaches a certain (Hg) then shut off and hold its pressure, or does it constantly need to be running.

As AJ always likes to say "Subscribed"... ;)

 :stupid

Subscribed :D

AJ

GIZMOGAMES

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #24 on: June 22, 2013, 04:57:20 pm »
OMG mountain most people do this stuff as a hobby ..
You my man treat this like an OBSESION your tools are amazing and your end results speak VOLUMES :D
subscribed yet again :)

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #25 on: June 24, 2013, 09:51:36 am »

Finally able to post some progress, at least on the fixturing.


I needed an easy and efficient way of trimming up the bottom edges of the curved piece. At first I was trying to come up with a clever jig to do the job. I soon realized I was making such a simple task way too complicated. The table saw sled would do just fine. I bought a new table saw recently and had wanted to make one for it anyway. They are extremely helpful and can make several tasks much safer.











One of the biggest challenges when using a CNC is holding the the work piece down. Clamps are the most popular choice in the DIY world because they are cheap, but they are usually clumsy and time consuming to setup. It can also be challenging when two sided machining is necessary. Indexing the part from one side to the other is much easier with a dedicated vacuum fixture. Once the front machining operations are complete, the part will be released and flipped over. With the X and Y reference stops in place, the vacuum pedal is pushed and its ready to go.


Channels for the vacuum and foam gasket cut into a 3/4" piece of HDPE.







The gasket installed.











Here is the inlet for the vacuum.











This foot switch allows me to position the part just right before turning the vacuum on.






Here is a short video of everything in action. As the foot switch is activated, the part is drawn down to the fixture, the pump refills the reservoirs and shuts off.


« Last Edit: June 24, 2013, 10:03:22 am by mountain »

orion

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #26 on: June 25, 2013, 09:55:31 pm »
That's pretty slick!

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #27 on: July 16, 2013, 12:25:52 pm »

I finally have some progress to post. I had a noise problem with the hall effect switches I use for limits on the CNC. It was causing erratic behavior in a lot of areas. So I had to tear down and do a bunch of re-wiring. It is all working great now. Hopefully no new issues with the machine for a while. My daughter's softball season is wrapping up this week, oldest's graduation activities are over, and vacations have been taken. Time to knock out some jukes!


Here is the front panel I made using 1/2" ply and .063" aluminum.








Back cuts for monitor and marquee inserts.



















Here is another front I made using the tried and tested black acrylic. Should look pretty sweet with the wood top.










abispac

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #28 on: July 19, 2013, 07:13:23 pm »
amazing  :cheers:

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #29 on: July 22, 2013, 10:04:44 am »

To dress up the edged of the jukebox top, I found some mahogany that matches the sapelle pretty well and will darken with age to add some contrast. I cut out some pieces and did the glue up.











Once the glue up was done I made a jig to mount to for machining. Nothing fancy, just a piece of plywood with reference marks to help line it up square. I screwed into the edge piece from below.


Here are some shots taken during the machining process. I made two of these, one for the front and one for the back.














mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #30 on: September 11, 2013, 09:24:28 pm »

Time for an update. It's been a busy summer and the design process on these new jukes came to a halt several times in the last few months. I finished cutting and testing and will be assembling (with glue) this weekend. In the meantime here are some pictures of the prototype parts.


Here is the front. This front has the gloss black acrylic, not aluminum.





The back machining, pretty straight forward.










The back panel will have a hinged door via the Soss 101 hidden hinges. They are a bit pricey, but the work great. The "production" parts will have the hinges at the bottom of the opening as the hinges sag a bit when used horizontally and make the door bind.



















I have made a few different tops to experiment with. The standard kits are going to be all black. Customs finishes will be available though. The two wood grained tops below are the same wood (sapele) with different stains and clear coats. The darker of the two is my favorite, but it hasn't been buffed out yet. It has a clear nitro lacquer and still has a few more weeks to cure yet. The lighter one is straight shellac and has had some buffing done to it, though only on the top.
























DaOld Man

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #31 on: September 11, 2013, 09:37:33 pm »
 :notworthy:

Rick

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #32 on: September 11, 2013, 09:45:09 pm »
:notworthy:

I'm with DaOld Man here. Not too shabby, Mountain.

emphatic

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #33 on: September 14, 2013, 08:30:21 am »
 :notworthy:

Typefighter01

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #34 on: September 14, 2013, 08:50:29 am »
This blows past DIY, this is commercial manufacturing out of a mans garage...awesome.

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #35 on: September 15, 2013, 12:51:35 pm »
Amazing!

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #36 on: September 15, 2013, 11:43:30 pm »
Man is it fun to watch you work!
Just Amazing :cheers:

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #37 on: September 16, 2013, 12:23:10 pm »

Thanks guys!
Here are some more progress shots.


I glued up the first unit over the weekend. I went with a black top since these are ones that most people will buy. The first step was to glue and clamp the bottom to the bent frame. Once that was dry I moved on to gluing the front and back to it. Most builders probably wont have this many clamps available to them so I will be offering this service as well.






Once the unit was glued up, I trimmed the edges. I intentionally made the front and back edges a little oversized for trimming later. This is to give a little bit of wiggle room when clamping. This ensures that once it is built and trimmed, the front and back panels are flush to the bent frame. This is important as the t-molding will be overlapping the bent frame structure about 1/8'. If it was off a little, it would stick out like a sore thumb.






Here is the monitor mounting bracket. It bolts to the back of the monitor and then to the side wall once it is properly aligned. It is made large enough to accommodate a mini-ITX motherboard and a hard drive. The holes are oversized allowing for adjustment. The half round slots in the pockets are for glue to escape when clamping, making sure that it is the right width when dry.









Finally, here is the I/O panel. Cut from .100" aluminum, it mounts from behind and held in with glazing clips. The screws will be stainless steel and match much better than the black ones here.






« Last Edit: September 16, 2013, 12:25:18 pm by mountain »

CoryBee

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #38 on: September 16, 2013, 12:42:41 pm »
 :applaud:

emphatic

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #39 on: September 16, 2013, 12:42:53 pm »
So. Damn. Sexy.  :cheers:

Superfrog

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #40 on: September 16, 2013, 03:39:53 pm »
I got a boner when I see all those fine details  :applaud: :applaud: :applaud: :cheers:

Rick

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #41 on: September 16, 2013, 04:11:53 pm »
I got a boner when I see all those fine details  :applaud: :applaud: :applaud: :cheers:

Note to Mountain: lower resolution images are in order.

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #42 on: September 16, 2013, 06:05:57 pm »
Not much more to add really - everyone has said it already!

EXCEPT:

a) is your volume going up to 11
b) are you putting any of these in?

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #43 on: September 16, 2013, 06:42:48 pm »
Not much more to add really - everyone has said it already!

EXCEPT:

a) is your volume going up to 11
b) are you putting any of these in?


Funny you should ask. I rebuild old radios and old tube amps. Once I get the time I have plans to make myself one of these for personal use. I think it would be sweet to incorporate an old radio dial and antique speaker cloth where the marquee is as well as throwing tubes in somewhere for show. I may save the tube idea for my antique radio console that I have ripped apart waiting for a touchscreen and TLC.

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #44 on: September 16, 2013, 06:57:30 pm »
 :notworthy: :notworthy: :notworthy:

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #45 on: October 27, 2013, 08:18:39 pm »
The new kit design is done and I have completed the first build this weekend. I decided to build one from the wood veneered top since I had worked on it so much. It is wrapped in Sapele veneer. I blended some different colored dye stains together until I got the tone I wanted. Then I sealed it with clear nitro lacquer. Three full cans of it actually. This stuff takes months to cure before you can start sanding it. Once it was ready I wet sanded it flat with 600 grit paper. Once it was flat and smooth, I went up through the grits, stopping at 2000. From there I buffed out the finish with rubbing compound and finishing paste.






























« Last Edit: October 27, 2013, 08:40:30 pm by mountain »

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #46 on: October 27, 2013, 08:27:05 pm »
Here are a few for shots of the inside and back. It was a quicky, I still need to wire the power switch and make the marquee light box.









Drnick

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #47 on: October 28, 2013, 12:32:09 pm »
 :applaud: :applaud: Damn that's some High quality finish!  :applaud: :applaud:

emphatic

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #48 on: October 28, 2013, 02:45:16 pm »
OMG!  :cheers:

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #49 on: October 28, 2013, 07:19:30 pm »
Thanks guys!
Here is what the standard black laminate kits look like clued together, polished, and t-molding installed. This prototype is for sale, assembly and polishing at no extra cost. Kits are now available here.








DaOld Man

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #50 on: October 28, 2013, 07:52:51 pm »
Good work from the Master!
I am digging the finish you put on the wood grained one. I think that looks better than laminate.

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #51 on: October 29, 2013, 07:37:03 am »
Good work from the Master!
I am digging the finish you put on the wood grained one. I think that looks better than laminate.


Thanks buddy. Yes, I agree. I wanted to build one like that to show what can be done. I will be offering unfinished wood veneered top options soon.


How's the juke build coming? I saw you got the first skin on.



DaOld Man

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #52 on: October 29, 2013, 10:34:04 am »
It's coming, slow but sure. I got the first skin on halfway. I ran out of glue, so I got to pick some up today before I can finish that step.

yotsuya

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #53 on: October 29, 2013, 10:39:24 am »
***Build what you dig, bro. Build what you dig.***

jongunz

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #54 on: October 29, 2013, 01:56:05 pm »
This looks awesome, but what do you typically plug them into for sound?  I thought the idea for jukebox systems were to have everything contained into the unit such as speakers etc.  Looks like you will need to run this into some kind of powered speaker cabinet.  Would be curious to see what the entire system looked like together.  I'd assume if you have some kind of surround sound system you would just plug up into that. Sorry if this sounds like a dumb post, but I was just curious.

mountain

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #55 on: October 29, 2013, 02:37:42 pm »
This looks awesome, but what do you typically plug them into for sound?  I thought the idea for jukebox systems were to have everything contained into the unit such as speakers etc.  Looks like you will need to run this into some kind of powered speaker cabinet.  Would be curious to see what the entire system looked like together.  I'd assume if you have some kind of surround sound system you would just plug up into that. Sorry if this sounds like a dumb post, but I was just curious.


Not a dumb question at all. It is just a "head unit". These are designed for bartops or other table top surface that may be available. I think most bars in the home or even mancaves will have some sort of entertainment system anyway. The small size of the speaker system that would fit in one of these jukes, if designed that way, wouldn't be loud enough in that environment. I have the one pictured sitting in my entertainment cabinet. It is nice to have a source with so much music.


If demand calls for it, I will design a base that has a speaker system in it, similar to the original I built in 2008. It will make the overall unit around 4 inches taller, which I think takes away from the look. But maybe that's just me.

Rick

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #56 on: October 30, 2013, 11:30:48 am »
I wanted to build one like that to show what can be done.

What you mean to say is "what you can do." Or, can you explain to me why it is yours look like this, and mine look like this?



;)

Again, godlike work sir.

system01

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #57 on: November 02, 2013, 09:29:17 pm »
Holy sheepshit!  We might as well have Midway or Stern come on here and say "You guys suck!  This is how it's done."

Hockeyboy

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #58 on: November 06, 2013, 04:17:54 am »
Holy sheepshit!  We might as well have Midway or Stern come on here and say "You guys suck!  This is how it's done."

This pretty much sums it up. I most certainly don't have the tools *or* the skills ( :'() to do this kind of craftsmanship. Well done, sir, well done.  :applaud:

I'd love to build a jukebox, but if I were to do so, I'd want it to have speakers included, with even the subwoofer inside. Well, if that would make sense to do it that way.

drwfandan

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #59 on: January 07, 2017, 06:51:55 pm »
I still find myself coming back to this thread on a regular basis. I wanted one of these as soon as I saw the pics. Unfortunately, the timing of me having the extra cash and these still being made just didn't  line up. If anyone knows of any other options for something even half as pretty as this could they please send me in the right direction. I do not have the woodworking skills to pull this off alone.

cyberphox

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #60 on: August 05, 2018, 09:03:30 pm »
are these kits ever going to be available again??

bperkins01

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #61 on: August 06, 2018, 01:44:50 pm »
I'm glad you popped it back - its from before my time here - very nice thread.
My Arcade Build and other projects here:
https://bperkins.wordpress.com/

Ian

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #62 on: August 12, 2018, 10:55:24 pm »
Mountain hasn't been on here for a while... I did buy one of these kits for a buddy and it still looks and runs great. Thanks Mountain!
Every normal man must be tempted at times to spit on his hands, hoist the black flag, and begin to slit throats.

cyberphox

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Re: Mountain Jukebox version 2 Prototype Build
« Reply #63 on: September 11, 2018, 07:46:00 am »
Yeah he hasnít logged on in a bit and website is expired. Does anyone have contact info for him?

  
 

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