So beautiful Spring weather has arrived in Texas, and with it, my opportunity to get moving on the 'outside' portion of the build. Woodworking has begun!
I won't go into lots of detail about this process, but I will say, if you have access to professional tools (full size table saw, router table, large work surfaces), the job is a lot easier. Unfortunately, I don't have access to those items. But, with a few key tools, and some extra time you can achieve the same results.
The tools that I have found to be invaluable for both my Arcade build and this Pin build are:
- Circular saw with a fine tooth blade
- Jig saw with wood finish/smooth cut blade
- Metal saw guide (worth its weight in GOLD)
- Clamps to hold the saw guide TIGHT (but without damaging the wood)
- Big T-Square
- Big 'L' Square
- Accurate ruler (in my case with Millimeters, since I'm following metric plans this time)
- Router (best tool ever?)
- Assorted Router bits (Flush trim bit, 1/16 slot cutting bit for starters)
- Router circle jig
I make almost all of my cuts with the jigsaw, guided by the metal saw guide. The jigsaw is just easier to control, and the blade is much smaller/narrower, so it makes more accurate cuts than the circular saw. But, the circular saw is invaluable for one simple thing: 45 degree cuts, as needed for the front and back joints of the cab.
I tell you, the age old adage of 'measure twice, cut once' was in full effect. In my case, it was measure 3-4 times, cut once. Can't tell you how many mistakes I saved myself, when I realized on my 3-4th measurement that something was off, especially after working for a few hours. That ruler gets harder and harder to read right when you're tired!

So anyway, here's a few snaps of the process so far:



Woohoo, a finished side! Exciting right? Yeah, until I realized I was a little too careless with my cutting on that piece and screwed up the dimensions of the top. Lesson learned. Luckily there was enough ply on the second sheet to make a new one.

Hey, a puzzle!

After a while I became a machine; I got to where I could cut the pieces to within a fraction of a millimeter tolerances. But all of the working on the ground sure took its toll on me physically. After two days of kneeling, leaning over, measuring and cutting ad nauseam, boy am I sore!

So a table saw not only would have probably taken 1/3 of the time, but it would have saved me a lot of back pain. Ah well, I guess it's like a woman giving birth, the pain only lasts a short time, but the reward continues on.

Now that all of the shapes are cut, I have to start working on all of the detail work like holes for fans, subwoofer, coin door, buttons, etc, etc.. Stay tuned!