Kits for this project are now available here.
EDIT: Here are the completed pictures in case you don't feel like searching all of the pages. Scroll down to read the original post.
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*Begin original post*I am taking a break from
my Fantasy Cab build to focus on this new project that came up. My Father recently announced that he will be retiring July 1st. The whole family will be converging on their house May 31st to celebrate. This always includes late nights downstairs having a few drinks at the bar. After showing my Mom the in-wall Jukebox/Digital picture frame I installed in my house last December, she knew that my Dad would really appreciate one down in the bar. So... she asked me to build him one as one of the gifts from all of us kids (4).
I have less than a month to build it so I went at it pretty hard this weekend. I sketched up a few ideas Friday night and decided on the one below. It has a retro feel somewhere between an old tube radio and and old jukebox.
The first thing I had to do Saturday morning was fix my circle jig I made for my router. I built an adjustable one years ago out of MDF but the slide mechanism I made finally wore out. Once I fixed that, I was ready to go.
I made the template for cutting out the jigs.
After cutting the jigs, I bore some holes to help with the clamping.
I screwed jigs to the base and added some temporary inserts to ensure the proper spacing.
I placed some tape on the bottom edges to keep the glue from bonding the bottom and sides. I need to remove the bottom and do some work to it before it can be permanently attached. I also put tape on a temporary strip of wood that will be used for clamping.
Saturday morning I ran out to get some suppies at a specialty woodworking store and discovered that they carry 1/8" MDF. I have heard of it before but had never seen it anywhere. I figured this was thin enough to bend so I grabbed a sheet. Here is a picture of the 1/8" on top of a 3/4" piece for reference.
Here is the first layer of the 1/8" MDF clamped around the curve.
After the glue set I used my router and a flush trim bit to trim off the excess material. I then sanded down the rest. now I have a better idea of what the final product will look like.
Here is a close up of the wrap job.
Here is the second layer of 1/8" MDF Glued and clamped.
I had to stop here because I really wanted all of the glue that it took for the second layer to really set before I started trimming it. I have to get the second layer trimmed and cut before I can continue because the final shape will be my template for cutting out the face of the jukebox.
More updates will follow.