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edekoning:
Yeah, first doing a dry fit makes sense, as I might also want/need to add/glue some additional pieces of wood, which is more work/annoying when everything is already painted.

--- Quote from: vertexguy on May 22, 2020, 02:29:10 am ---
--- Quote from: edekoning on May 21, 2020, 10:18:55 am ---Added a very small chamfered edge, just make it look nicer. Really happy with results on this panel.

--- End quote ---

I really like that look. This is the same style vents I was looking to make. But you made it even nicer. Can you share more detail to a novice on your technique?

--- End quote ---

Use a pencil to clearly draw out the vents you want to cut.
Make sure the slots have the same height as the diameter of the router bit that you will use; I used a 1/2" diameter straight router bit.
I used the track (from my track saw) to restrict the movement of my router, so it could only move left and right across the vent.
I also clamped two strips of wood to further limit the horizontal movement to just the area of the vent I need to cut.
Alternatively, you can nail or clamp some pieces of wood onto the work piece to restrict the router's movement.
In that case, make sure the router bit has a top bearing, so it can follow/copy those clamped/nailed pieces of wood.
Take your time, don't rush and take multiple passes.
Once done, use a 45 degrees chamfer router bit with a bottom bearing. The bearing will ride the inside of the slot.
Make sure this bearing is the same diameter or smaller as the width of the the slot, otherwise it won't fit :)

If you scroll up a few posts, there are pictures that clearly show the chamfer router bit I used, and also how I used some nailed woodstrips to guide the straight router bit.

edekoning:
I added the battons to the side panels.

In order to get close to identical results on both side panels, I made some simple helpers for positioning the battons at the correct distance from the edge.
All panels are offset either 1/2", 1", or 1.5" from the sides. The panels themselves are 3/4". Add those up and you have the position of the battons. So I cut some wood strips with with the same widths as the offsets I needed. Next, I glued on some small pieces of wood to the edge. Then I just place this thing on the side panel against the edge, and clamp it down. Next place/clamp the batton snug against it, drill the holes for the screws, and glue/screw it in place.

edekoning:
Now that the battons are in place, I could finally measure and cut the bottom panel.

Even though I have a universal router circle cutting jig, I could not use it for the bottom panel, as it cannot cut such a small circle. Instead I used a jigsaw. By no means a perfect circle, but good enough for the bottom.

I also cut these additional spacers for the bottom and lower back panels. These are needed for mounting the wheels. Unfortunately, I forgot that the spacers for the back panel need to be 10mm and not 18mm ... so I plan to just glue them on the back panel, and then route away 8mm. As its raining today, that will have to wait till next weekend. Once that is done I think I can start screwing most of the panels in place. Its only the speaker panel, monitor mount, monitor bezel, and control box that still need wood working.

vertexguy:

--- Quote from: edekoning on May 24, 2020, 10:44:18 am ---If you scroll up a few posts, there are pictures that clearly show the chamfer router bit I used, and also how I used some nailed woodstrips to guide the straight router bit.

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Thanks. I have zero experience with a router. Mine doesn't have a plunge cut feature on it. Will that be a problem? I assume when you say make multiple passes, you mean start at a shallower depth and with multiple passes you're going deeper with each? I got a small set of bits online for it, not really knowing what I need. Hopefully one of them is a chamfer bit.

edekoning:

--- Quote from: vertexguy on May 24, 2020, 02:12:32 pm ---Thanks. I have zero experience with a router. Mine doesn't have a plunge cut feature on it. Will that be a problem? I assume when you say make multiple passes, you mean start at a shallower depth and with multiple passes you're going deeper with each? I got a small set of bits online for it, not really knowing what I need. Hopefully one of them is a chamfer bit.

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Ah that complicates matters. I would probably drill a hole first with the exact diameter as your router bit. Then place the router with the bit inside the hole. Be careful when switching it on though, as the router might jump when it starts and catches the wood. Less of a risk if your router has a slow start feature. Anyway I suggest to try this out first on a spare piece of wood.

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