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Someone call the cops! I stole a Jukebox!! MAGNETS??? [03.05.2009]
javeryh:
Back in July I started working on a new project and I wanted to make a little progress before announcing it. Before I start documenting everything I've done so far I want to give a HUGE thanks to mountain for (1) building his awesome Jukebox which I am shamelessly ripping off and (2) his patience in answering a ton of questions that I keep asking him about parts, designs and other issues. :cheers:
Since mountain's build is way out of my league I had to modify his design a bit to suit my skills. I am not incorporating the rotating base and instead the marquee, monitor and speakers will all be contained in one box. The entire front will basically look like this with three openings:
The goal for the first night was simple - all I wanted to do was create a template for cutting out the front and back panels of the jukebox. The dimensions of the template are as shown in the picture and it is made out of 3/4" thick MDF. The only real tricky part about making the template was cutting out the curve with my router and circle cutting jig and having it transition perfectly into the straight sides.
Next up is cutting out two identical panels to be used to help form the overall shape of the jukebox.
:cheers:
javeryh:
Now that I had a pretty good template, the next step was to use it to make two identical panels. First, I traced the template with a pencil onto 3/4" MDF and cut the panels out with my jigsaw staying about 1/8" outside the line.
Then, I clamped the template to the top of each of the panels I just cut out and used my router and a pattern bit to make two exact copies of the template. These panels will eventually be the frame for the front and back of the jukebox.
Finally, I cut out eleven (!) 2" holes close to the edge of the front and back panels (what a pain) for clamping.
Next step is making this thing 3D! :cheers:
javeryh:
Next, I cut out the base and the interior spacers - I made each panel 9-1/2"x15-1/2" (the exact size of the base). Then I screwed everything together to get the general shape of the jukebox. I'm using screws here because once the glue dries from attaching the curved panel I'll be removing the bottom and the interior spacers. The only thing to note is that the front and back panels have to be EXACTLY opposite each other.
Next is gluing up the curved panel to the shell. :cheers:
javeryh:
Next I glued a 1/8" hardboard panel to the shell and I was praying that it would bend along the curve without breaking (or putting a serious amount of tension on it). It worked even though the hardboard really wasn't made for bending.
This forms the sides and top of the jukebox - now we are getting somewhere! I'm actually using two 1/8" sheets so the final thickness of the top and side panels will be 1/4" to give it a little more strength. In order to hold everything in place while the glue dries I used those holes I cut out in the front and back panels.
Next up once the glue dried is to use my router and flush bit to even everything out and then glue the second layer of 1/8" material giving me a 1/4" thickness on the curved panel. :cheers:
MinerAl:
Very cool start.
Keep us updated!
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