I've now completed this cab build! Before I show you final pics, I am going to write up some steps.
BEZELI based my bezel design on the
"$2 cardboard bezel" from nearly 20 years ago. Except in my case, it cost about 50 cents, even with inflation! It is my first attempt at a fully "3D" bezel. As I got into it, with experience, it got easier.
Started with a large sheet of black light cardboard. It is really quite light cardboard, at first I worried it wouldn't be strong enough, but as it happens it worked just fine.
The most important measurement is the diagonal ("hypotenuse") from screen corner (phosphor edge) to the corner where your edge supports meet, and then the straight from screen corner to closest edge support. This gives you two sides of a right-angle triangle, which makes it easy to find the third side. There is no need to find the other angles.
You can do this by applying a little good-old Pythagoras:
Side B=√(H
2 - A
2)
At first I found the third side by just moving my ruler until the hypotenuse (8cm) connects with the end of Side A (~3.5cm). Then Side B is obvious. This is how I did it at first, and thus my measurements are a little rubbery, but it is close enough, re-checked later using the maths.
I included ~2.5cm along each side for support. By leaving them long for now, I can trim and glue them to other pieces later for extra stability.
Once I got the lines worked out, did some cutting. Left extra material to make tabs, about 1.5cm wide, that will bend backwards and out-of-sight. These tabs will be important later for holding everything together.
I use a metal ruler to help make the folds straight and proper. It is important to try for hard, sharp, clean folds if possible. For the longer folds, clamp down the ruler. If you don't have a metal ruler, you could fold against a straight piece of wood. I used a smaller plastic ruler to help push the cardboard up evenly for the folds, without damaging the front surface.
For the top piece, I just flipped the bottom and traced it out. This comes out a little large as the bezel support is a bit closer/tighter, "hypotenuse" only about 7.2cm. Not to worry, we'll trim that back soon
To cut out the curve of the screen, I approximated a curve using my trusty metal ruler and a few small nails. Then it is simply tracing out the line and cutting it out.
Now the bottom and top parts are done, time to do the sides!
The two sides came together quickly because I already know critical measurements (hypotenuse, Sides A & B). Again I included tabs and side supports where possible. I was able to use the same curve/nails as for the bottom/top pieces, just made sure to get the middle in right spot. The only nail I had to move was the middle one (and it goes back, through the bezel, into the same hole.
Once I had the pieces, it was time to put them together. At first I used some foldback clips to hold the pieces in place. Then, with a bit of jiggling and trimming, was fairly happy with the results. Once happy, I used a stapler to connect the tabs from behind. Looking pretty good now.
NEXT: FINISHING TOUCHES