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Author Topic: The Grid....  (Read 40342 times)

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Arroyo

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Re: The Grid....
« Reply #320 on: September 03, 2019, 02:56:44 pm »
I realize that I start every new post with “got a chance to work”, I guess I’m just trying to keep this gravy train of time going, cause so far the wife and extended family have been really helpful in freeing me up….hopefully that means they want this thing built as bad as I do.….  :dunno (yeah sure).

I needed to redo the curve support piece as it wasn’t quite even spacing on both sides, that and I mucked it up when trying to do a duplicate. 



It actually took me quite a while to figure out how I was going to make 10 more of these things.  Seemingly it was trivial, just double stick tape and use it as a template on the router.  The problem is that this piece is so small that your hands end up being really close to the 30,000rpm spinning blade.  I tried using push blocks but the piece would tilt as I put pressure and tried moving it around…..So I took a discarded straight piece that I had made a mistake on and drew out the 10 additional using the above as a trace.  Rough cut with a jig saw:



Then placed the template on the outline to get the proper curves (put some blocking to support as the thin part liked to move):



This longer piece allowed me to move it around without worrying about my hands getting chopped.

Placed that on the table blocked by another piece (check out the double stick tape graveyard):



Busted out my new toy:





Needed to separate the last bit at the thin part, so I made myself a poor man’s band saw (jig saw clamped upside down):



Stupid amount of time to get this result:



Next problem was cutting some angles.  I had already done all of my miter (beveled?) cuts, and two pieces weren’t aligning.  The two pieces called for 62 degree angles.  I thought I was being smart by flipping over the piece and cutting the opposite angle of 28 degrees.  The reason I was doing this is the track saw (and really any circular saw), is limited to a 45 degree angle.  Well I wasn’t smart and this didn’t work.  You can see the angle I cut, and after fitting it to the paired piece, the angle I needed:



Gave up trying to figure it out and asked for help from my usual source (thanks again buddy).  I was on the right track with opposite angle, but to get it you need to cut the piece from the top (or in the picture the left side edge).

Doing this however meant getting the pieces to sit up straight and not move.….. for all you pro’s you might want to look away:



This is the best I could come up with.  The top pieces is a sheet of 4’x8’ that is still mostly unused.  The piece touching it is actually the back door to the machine that I already cut, which miraculously lined up with the height of the plywood on the saw horse.   Double stick taped to the door is a piece of sacrificial plywood, and double stick taped to that is the test piece I was using for getting the cut.  Lined up the track saw to the edge, then offset 2.5mm to account for the thickness of the blade, and voila, finally got my angles:



Was excited to throw some pieces together:



Didn’t have quite enough clamps to get everything fitting tightly, but it was cool nevertheless. You can see at the bottom the curve on the sides.  Behind that coin door panel is where the curves will attach to the base, and provide the support for the coin door to curve at the bottom……getting there.



« Last Edit: September 20, 2019, 01:21:01 pm by Arroyo »

Mike A

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Re: The Grid....
« Reply #321 on: September 03, 2019, 03:27:51 pm »
Nice work. Make sure you maintain a healthy respect for that router. It will try to murder you.

bperkins01

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Re: The Grid....
« Reply #322 on: September 03, 2019, 03:32:39 pm »
Nice work Padawan learner    :applaud:
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uptown47

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Re: The Grid....
« Reply #323 on: September 04, 2019, 08:02:48 am »
Great update, really nice to see it coming together. :-)

opt2not

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Re: The Grid....
« Reply #324 on: September 04, 2019, 02:21:39 pm »
I'm trying to wrap my head around those curved support thingies.  What's their purpose, and why do you need 10 of them?

Arroyo

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Re: The Grid....
« Reply #325 on: September 04, 2019, 04:22:58 pm »
I'm trying to wrap my head around those curved support thingies.  What's their purpose, and why do you need 10 of them?

So yeah, if you look at the picture below and imagine pulling the bottom of the coin door where the red arrow is towards you so that it lined up with the curve on the "sides" of the machine (blue arrow), so that they line up:



To bend the coin door like that I will be cutting slots into the back of the board (kerfing), so that the board will bend, and the curvy thingies will be behind that board attached to the base to support the curve:



Does that make sense?

Arroyo

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Re: The Grid....
« Reply #326 on: September 04, 2019, 05:08:59 pm »
One thing that I wanted to mention was the painful learning experience of direction of the blade and thinking about how to approach a sharp angle.  Notice below the fractured tip of the triangle sides:



That happened because the blade was spinning in the direction away from the piece, meaning as it got closer there wasn't any support for that frail amount of wood and consequently some pieces chipped off.   This really hit home for me when trying to cut those smaller curve thingies.  Once I figured out that the direction of the spin needed to cut into the heart of the wood piece I eliminated this problem:



So in the picture above the blade is spinning counterclock wise, so that when the blade hits the small part of the curve thingy (see black arrow to the left), the cut is supported by the rest of the wood of the same piece.  If it were the opposite and the blade was spinning clockwise, once you get towards that tiny part it has a tendency to rip off a piece of the wood and fling it into the open air.  Hope this helps someone avoid the same mistake.

EDIT:  Perhaps I jumped the gun on this one.  This may be incorrect.  I’ll let a more experienced woodworker comment.
« Last Edit: September 04, 2019, 06:27:38 pm by Arroyo »

opt2not

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Re: The Grid....
« Reply #327 on: September 04, 2019, 07:28:15 pm »
Does that make sense?
Yes, thank you. That's clear now. Sorry, my brain must have farted.

Mike A

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Re: The Grid....
« Reply #328 on: September 04, 2019, 07:41:12 pm »
The cab is ribbed for his pleasure.

bperkins01

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Re: The Grid....
« Reply #329 on: September 04, 2019, 08:09:34 pm »
I was conversing with Arroyo and suggested a way to make this w/o some of the potential for issues.

More on this idea:



1. Cut the majority of the blank out near the curve line on an slightly oversized blank.
2. Add the template and use the router/pattern bit to cut to the exact curve - (the template would be for the curved part only obviously)..  The point is the pointy end would have a lot of backer board below it so it would not shred.
3. Slice off the bottom to create the pointy end (table saw or equal)
4. Cross cut the wide end to length..

No chances of the router bit throwing stuff.

At first I thought he was using hardwood and cutting with the router uphill against the grain..  (that would be bad)..  But its ok on plywood..

They are all made now - but trying to cut sharp points with a router scare me..
Still lovin' the progress!
« Last Edit: September 04, 2019, 09:04:13 pm by bperkins01 »
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Mike A

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Re: The Grid....
« Reply #330 on: September 04, 2019, 08:45:48 pm »
Yeah. That looked a little scary.

opt2not

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Re: The Grid....
« Reply #331 on: September 04, 2019, 08:55:06 pm »
Shoulda just got Mike to CNC those things quick for ya.  More precise, quicker, and safer.

Arroyo

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Re: The Grid....
« Reply #332 on: September 04, 2019, 09:40:06 pm »
Shoulda just got Mike to CNC those things quick for ya.  More precise, quicker, and safer.

Now where would be the fun in that?  ;)

That would have been smarter and easier, I seem to like to do things the hard way.
« Last Edit: September 09, 2019, 11:35:38 am by Arroyo »

Arroyo

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Re: The Grid....
« Reply #333 on: September 04, 2019, 09:40:37 pm »
The cab is ribbed for his pleasure.

He gets it.

Arroyo

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Re: The Grid....
« Reply #334 on: September 09, 2019, 12:10:13 pm »
God I love SketchUp.  I don’t know how I would have figured out all of these angles without it.

As I had everything already setup to do so, I continued making angled cuts.  The last batch (fingers crossed) was for the monitor surround area which involved a lot of angled cuts.  One challenge was that the circular saw leaves a fair amount of material on an inside corner.  I had purchased a Makita Palm router with a tilting base to trim laminate and decided to try it out on this:



Actually worked really well, and it is a much better overall quality router than my Ryobi as it has speed control, tilt, and swappable bases (also has a plunge base), and vacuum hose attachments.

Finished off the inside corners with the Jigsaw tilting it to match the angle, turned out pretty well:



Then had to miter a number of angles on the triangle pieces, so had to come up with a solution to lay down the track saw:



To get this result:



These act as a brace to support the monitor surrounds on a tilt to match the monitor so that they are in parallel.   Here’s a pic from the back to see it all lined up:



And the front:



Also mitered the speaker panel, and hopefully no, more, miters…That should just leave the triangle support pieces, kerfing, and eventually hole cutting….although I always underestimate this stuff.  Oh and if your wife ever asks you to install a Reverse Osmosis system in your kitchen, don’t, it’s an all-day affair  :angry:
« Last Edit: September 09, 2019, 01:17:30 pm by Arroyo »

Mike A

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Re: The Grid....
« Reply #335 on: September 09, 2019, 12:23:42 pm »
Dude. This build would give me nightmares with its complexity. Kudos to you for all of your progress.

I think my cab has 3 angled cuts.

javeryh

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Re: The Grid....
« Reply #336 on: September 09, 2019, 02:34:18 pm »
Wow the angles are making my brain hurt.  Looking good!   That little router looks like fun too.  Can't wait to see this thing put together.

You should have bought your wife a Brita! :cheers:

Mike A

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Re: The Grid....
« Reply #337 on: September 09, 2019, 02:38:47 pm »
It looks like a murder box. You could impale someone on that thing.

bperkins01

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Re: The Grid....
« Reply #338 on: September 09, 2019, 02:47:00 pm »
 :applaud:
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gingecko

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Re: The Grid....
« Reply #339 on: September 09, 2019, 02:52:52 pm »
I've been looking at palm routers, and the Makita one sounds pretty nice. I could really use something that is in-between my Dremel tool and the old Skil workhorse router I have.

Your project is looking great. I just hope that one day I understand it!   :laugh:

Arroyo

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Re: The Grid....
« Reply #340 on: September 09, 2019, 03:34:24 pm »
I just hope that one day I understand it!   :laugh:

Me too :dizzy: feels like a rabbit hole every time I go to cut something.


@bperkins -  8)

It looks like a murder box. You could impale someone on that thing.

 :laugh2:  almost fell out of my chair.

Wow the angles are making my brain hurt.  Looking good!   That little router looks like fun too.  Can't wait to see this thing put together.
You should have bought your wife a Brita! :cheers:

 :cheers: I'm diggin the router, feels like a much higher quality product compared to my workhorse Ryobi.  And yeah Brita FTW.

Dude. This build would give me nightmares with its complexity. Kudos to you for all of your progress.

I think my cab has 3 angled cuts.

Over-complicated is my middle name.

bperkins01

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Re: The Grid....
« Reply #341 on: September 09, 2019, 03:54:52 pm »
Arroyo - the Original OC.
 :laugh2:
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wp34

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Re: The Grid....
« Reply #342 on: September 20, 2019, 02:42:09 pm »
That is some quality woodworking Arroyo.  Next thing you know you are going to be building furniture.   :cheers:

Arroyo

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Re: The Grid....
« Reply #343 on: September 20, 2019, 05:48:14 pm »
You said it before wp34, and I think you’re right, woodworking is the best part of a build.

Kingcade

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Re: The Grid....
« Reply #344 on: September 20, 2019, 06:15:09 pm »
Love the design and woodworking! (I'm also a big Tron fan - I made a Tron board game when Tron:Legacy came out: )
KINGCADE - my Steampunk Wild West penny arcade-style cabinet
http://forum.arcadecontrols.com/index.php/topic,161105.msg1697383.html#msg1697383

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Re: The Grid....
« Reply #345 on: September 21, 2019, 12:56:35 am »
Looking great dude, keep it up!  :applaud:

Vigo

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Re: The Grid....
« Reply #346 on: September 21, 2019, 02:49:46 pm »
Love the design and woodworking! (I'm also a big Tron fan - I made a Tron board game when Tron:Legacy came out: )

Good work! 9 in posts may be a little early to say it, but I think you will fit in perfect here!  :cheers:

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Re: The Grid....
« Reply #347 on: September 21, 2019, 02:51:50 pm »

It looks like a murder box. You could impale someone on that thing.

 :laugh2:  almost fell out of my chair.


I am tempted to photoshop an MK character impaled on your machine.  :lol

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Re: The Grid....
« Reply #348 on: September 23, 2019, 12:35:34 pm »
Sorry long weekend, I was playing Mr. Mom, while the wife was gallivanting all over Napa with her friends.

I am tempted to photoshop an MK character impaled on your machine.  :lol
Do it!

Looking great dude, keep it up!  :applaud:
Good to hear from you JudgeRob  :cheers:

Love the design and woodworking! (I'm also a big Tron fan - I made a Tron board game when Tron:Legacy came out:)

That’s awesome, lightcylces are easily the coolest part of the Tron universe.  I’ve got one planted on my marquee as well.



Didn’t get too much time to work, but managed to get some stuff done.

Secured the curvy thingies to the base:







Secured a piece of wood under the base that stuck out so I could make sure that each piece was at the same height when mounting them.  I also numbered each one so I wouldn’t lose track when I take them off and glue them on.

Spent the rest of the time cutting battons/cleats/blocking, whatever you call them.  I managed to cut all of them including the angle cuts.  Came up with this simple way of using the track saw and pulling the length I needed while keeping it steady:



I also cut out the triangle supports that I need for securing the front USB panel to the monitor base  (small ones in the middle).  I now have almost everything cut (enough for assembly anyway).  Last thing is to do is practice kerfing, and then do it on the door:



Oh and I ordered a circle jig from Aliexpress for the Makita palm router.  Surprisingly well made, and a lot of options for cutting small to large circles.  Looking forward to trying it out:


« Last Edit: September 23, 2019, 05:53:24 pm by Arroyo »

Mike A

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Re: The Grid....
« Reply #349 on: September 23, 2019, 01:19:38 pm »
That's a lot of triangles.

Happy to see progress. :cheers:

Mike A

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Re: The Grid....
« Reply #350 on: September 23, 2019, 01:31:41 pm »

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Re: The Grid....
« Reply #351 on: September 23, 2019, 01:43:49 pm »
Looking good, and I'm starting to understand it now! ;)

wp34

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Re: The Grid....
« Reply #352 on: September 23, 2019, 01:51:28 pm »

Arroyo

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Re: The Grid....
« Reply #353 on: September 23, 2019, 06:18:46 pm »
Cheers fellas :cheers:

-Triangle Man

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Re: The Grid....
« Reply #354 on: September 24, 2019, 11:11:47 am »
I am enjoying watching this come together.   :applaud:

Arroyo

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Re: The Grid....
« Reply #355 on: September 30, 2019, 11:45:19 am »
Cheers Laythe  :cheers:

Finally time to start putting this thing together, well a little at least.

Started doing my first blocking:



Used ¾” poplar pieces, drilled, countersunk and then tried out the new impact driver that I bought.  I’ll echo Vigo’s comment on impact drivers:



I found it was best to measure the width of the Plywood and mark it on my ruler, then double and triple check the width from the blocking to the edge to get a flush finish once it was screwed down.  Worked pretty well.

Tackled the upper Marquee box and was happy to see the boards were cut to size properly and fit nicely:







Finally tried to tackle the kerfing of the coin door.  Was nervous about this one, and tried to look up a good way to calculate the spacing and depth between cuts.  I found this one site:  https://www.blocklayer.com/kerf-spacingeng.aspx

Which seems like it would be really handy if you were bending the wood in.  Since I am bending mine out, not quite as helpful, and probably indicated that it’s not as big of a deal as the spaces on mine fan out, rather than bend in to hit each other.
I measured the height and distance of the curve in Sketchup, and then marked out the total distance.  Practiced with spacing and depth on a spare piece and went with ¼” spacing between cuts.  I ended up leaving 3/32” depth remaining on the wood.  Drew it out, laid down the track saw and went to work:





Vacuum hose kept snagging the lower left corner, no biggie a little glue or wood filler and should be good.  Here’s a shot from cut level:



Attempted to mount it:



But had to stop as it became clear that I am going to need some strong glue and a lot of clamps.  The wood bends but only with a decent amount of force.  I will probably end up steaming the outside with a clothing iron, then clamp, or even use bags of sand as I thought this might contour to the curve more evenly then clamps would.  Plus the clamps would have to have a very deep throat.  Currently in this state:



That impact driver is the ---steaming pile of meadow muffin---, now I need a brushless drill too  ;D.  Damn this hobby is expensive.
« Last Edit: September 30, 2019, 02:38:57 pm by Arroyo »

wp34

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Re: The Grid....
« Reply #356 on: September 30, 2019, 12:07:01 pm »




Man that looks nice---especially when the picture is expanded to full size.  Looking forward to seeing the carcass put together.   :cheers:

Mike A

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Re: The Grid....
« Reply #357 on: September 30, 2019, 12:09:39 pm »
Progress. Hooray!

If you already have a cordless drill that works you really have no need for a drill with a brushless motor. Don't fall for marketing hype.

If you need more power than your cordless can provide than just use a corded drill.

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Re: The Grid....
« Reply #358 on: September 30, 2019, 12:13:58 pm »
Nice work   :applaud:

I think if you screw the coin door in place, use some foam across the length of the curved area and then a board across that.  You can use some clamps on the side and some zip ties to pull the board into the clamp for pressure while the glue dries.
 
ps.  You can never have too many tools  :)
My Arcade Build and other projects here:
https://bperkins.wordpress.com/

Mike A

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Re: The Grid....
« Reply #359 on: September 30, 2019, 12:17:43 pm »
You know. I was trying to help this poor guy out. I already have him in enough trouble as it is.