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Oops! There goes another Mountain Juke Box! (*05/04/2009*) Update

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DaOld Man:

Cut out laminate (or acrylic) routing guides for marquee, monitor, and speaker bar.

Got the router guides cut out. They turned out pretty good.
Had a little bad luck while cutting out the speaker guide. The sleeve on the pattern bit that holds the bearing down against the cutting part came loose and allowed the bearing to walk up the shaft of the bit. The bit went wild before I could stop it, cutting a dip out of the guide. Im hoping I can fix this with some well placed wood putty.

I looked at the monitor mounting plates again, and they now appear to be the same, so Im thinking about not routing out for those, unless someone can give me a good reason why they did theirs.
Didnt get to work on this today, but hopefully tomorrow afternoon I will get the 1/2" additions added to each side of the speaker box and be ready to laminate it.

Then I got to make the jukes back.

javeryh:
Looking good!

DaOld Man:
Thanks Javeryh.

Here are some pictures of my routing guides I made.
I plan to insert these guides into the cutouts for the monitor, marquee, and speaker bar after I glue the acrylic on the front.
I will then use these to guide the router bit to cut out the overhang I need in each of the acrylic openings. I can then remove the guides.

First, here are the guides for the marquee and monitor:



And here they are test fitted into their respective cutouts:



And here is the speaker bar guide:



You can plainly see where my pattern bit bearing messed up on me.

And here it is installed. I will have to place it insid eteh speaker box, and extend the bit up far enough to reach it:



I now have two pieces cut for each side of the speaker box to make up for the extra inch I added to the width of the juke box.
I had to bring the box and the pieces in the house to glue, I am afraid it is too cold out in the shed for the glue to set up good.
The kerosene heater keeps me warm, but the parts of this project are still cold.
I am waiting for the wood pieces to get to room temperature.

DaOld Man:
Got the 2 pieces glued to the speaker box. It is now the correct width:



I thought about a potential problem down stream.
The router guide I made for the speaker bar wont work with the 45 degree chamfer bit, so I tried to cut it down to fit the hole in the box.
The router broke the piece and ruined it.
So I made another one:



Here it is fitted into the hole:



I still need to cut out the area between the two round holes.
I still havent figured out how to do that, guess I am afraid the router with the pattern bit will break it.

This is going to hold up the applying of the acrylic and laminate because I want to be sure the router guide will fit before covering the hole with the 1/8" acrylic.

DaOld Man:
I got the speaker bar router guide finished.
It took me a lot of work.
I first drilled 1-1/4" holes between the two on the ends.
I then cut between the holes with a jig saw. This left a very rough edge.
I used my dremel tool to bring the cut right to the line, then I finished it with a lot of hand sanding. I had to be extra careful because of how thin the edges are.
Before I did anything I coated the entire outside edge with carpenters glue and rubbed it in good. I think this strengthened the piece of mdf considerably.
Here is a pic of the finished piece:



Here is a pic of the guide laying on the speaker bar:



You can see how the opening in the acrylic will hopefully line up with the speaker grill.

I also applied laminate to the top and the two end sides of the speaker box.



The corner needs a little more work, the white stuff you see near the front is actually a small piece of painters tape that Im having a hard time getting out.
I used the tape to protect the top edge from scratches from the laminate cutting bit.
(This may not have been necessary, I dont know.)

I have to pick up some wood putty tomorrow. The cutout for the power entry module is a little big around a couple corners. I need to fix that before applying the laminate to the back. I dont want a crack around the module.

I also need to figure out how to hold the speaker bar in. Im thinking 4 L brackets that will let me run two springs around the back of the bar to hold it snug against the front acrylic.

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