The black laminate is Wilson Art - Black 1595:
http://www.wilsonart.com/laminate/consumer/products/viewitem.asp?idproduct=474&idCategory=40and the Yellow is Pionite - SY914
http://pionitesamples.recol.biz/detail.aspx?id=4590If you never used laminate your missing a real treat. I truly is easy (and fun) to work with and makes even a hack like myself look like a professional.
I cut the sides then applied the black inside. A router bit has straight flures and a ball bearing for a guide. It cuts the formica perfetly straight as the bearing rolls on the edge of the MDF. I then used a centerdrill (machine shop item) to drill all the holes for the dowels and starter holes for the screws. A centerdrill has straight flutes and will not grab at the formica and try and pull it from the MDF. After centerdrilling for the dowels I then used a 3/8 formica cutter to just spot drill (countersink) the formica down to the depth of the MDF. That way the dowels don't actually touch the formica, again risking the chance of pulling it or chipping it. It sounds like a lot but is really quite simple. After all this I then glue on the Yellow and route the edge.
I cut my sides on a CNC milling machine. I am getting ready to make a 1/2" think aluminum master side. That way I can cut them all in my garage by just clamping the plate on a piece of MDF and using a router. I am also going to put drill bushings in the aluminum plate for a drill template for the 1/4" dowel holes. This should make building the next couple a breeze. I want to make another with a verticval monitor. I figure with the template I will be able to make a set of sides in about 15 or 20 minutes. I may make some extras if anyones interested and offer them to people on the board for materials costs and shipping (just a thought). Anyone interested?
You can email me at the address on my website at
http://home.comcast.net/~cpviewer . I'll help ya in any way I can.
be in touch,
John