Here's something I made for the heck of it. I don't even have a place to put it. I just made it to temporarily store a marquee and a florescent light fixture.
I didn't have my camera handy during construction so I will explain it briefly.
I made this thing in about 1.5 days. First I cut two identical pieces for the top and bottom out of 5/8" MDF then I cut mounting blocks out of 1.5" x 1.5" stock. I screwed the MDF onto the blocks, one at each end and immediately puttied the holes.
Then I cut one square out of MDF and then used my jigsaw to round out the corners. Once the piece looked the way I wanted (with a little sanding) I put it on top of another piece of MDF and used my flush trim bit on my router to make an exact copy. I use this method frequently for making perfect matching end pieces. It just makes it so perfect and easy.
While I had my router out I slapped on a slot cutting bit and ran it around these new pieces.
Then I screwed (countersunk again) through these new end pieces into the blocks mounted on the top and bottom pieces. Wood putty over those holes and then I started priming everything. I used a Kilz water based primer and it works great.
Then two coats of black with sanding in the middle. I mounted the light fixture next. If I had planned this properly, I would have drilled for the mounting screws prior to assembling the box but oh well.
I had purchased some marquee retainers from happ along time ago. I put these on my table saw with an 80 tooth blade and the cut was factory smooth.
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