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.   

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.

 

[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!   

[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.   

[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.   

[MinerAl]

Very cool start.

Keep us updated!

[gonzo90017]

 

[DaOld Man]

Looking good, JaveryH!

[javeryh]

Thanks everyone!  I'm actually a little bit further along - I'll keep updating when I get a chance...   

[DeLuSioNal29]

Looks good!  Can't wait to see more!

~ D

[javeryh]

After letting the glue set overnight next came the moment of truth... would the curved panel spring back or would the bond from the wood glue be enough to hold it in place? The clamps are off and so far so good!

Now comes the tricky part - removing the excess material that overhangs the edges. Normally this is an easy task with a flush trim bit and a router, however, going over the curve is going to be difficult. I had to clamp the jukebox in place and then go around the curve ever so slightly. The router base was not laying flat and it was a bit scary.

Success! Check it out - it is really starting to take shape:

[ivwshane]

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:

Omg shut up!! I think you are in the top 10 on this site easily!


lol, how many cabs/machines have you built already?




Oh, looking good so far:D

[javeryh]

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:

Omg shut up!! I think you are in the top 10 on this site easily!


lol, how many cabs/machines have you built already?




Oh, looking good so far:D

woah, thanks for the compliment  - although I can think of at least 30 or 40 people around here off the top of my head who are miles better than me and who knows how many more if I sit down and think about it.   

I'm in the middle of my 3rd cab and my 1st jukebox.   More updates on this tonight or tomorrow. 

[Kaytrim]

Hey man don't sell yourself short.  You are easily in that 30 to 40 that you would mention.  Keep it up I'll be starting mine soon.

TTFN 
Kaytrim

[javeryh]

Hey man don't sell yourself short.  You are easily in that 30 to 40 that you would mention.  Keep it up I'll be starting mine soon.

TTFN 
Kaytrim

Thanks Kaytrim.  I cannot wait to see what you come up with.  Have you thought it out yet?  Any teasers you care to share?   

[Kaytrim]

No teasers yet.  The design is still real rough and dependent on the hardware I am putting inside.  I thought that I would use an old laptop but it is too old (a PIII).  I don't want to hijack your thread anymore so I'll post some details in my thread soon.

TTFN
Kaytrim

[javeryh]

I'll be on the look out for your thread.  

Some more of the build:

After flush cutting the curved panel it was time to add another 1/8" layer to the curve to get to the final 1/4" thickness. This process is identical to what I did for the first 1/8" panel only this time I have a lot more surface to glue to. I was also able to use my two band clamps to help keep everything nice and flat.  You can kind of see the two layers in this blurry picture:



Before starting, I roughed up the surface of the hardboard with some 100 grit sandpaper so the glue had something to grab on to. I'm hoping the glue holds over time but so far so good...



Twisted Tea for scale.   

[javeryh]

The next step was to begin making the front panel.  After thinking about it for a bit I realized this part is going to take quite a bit of time. I did manage to cut out the general shape of the front in less than an hour though.

First, I traced the shape of the front of the jukebox onto some 1/2" MDF and rough cut it out with my jigsaw staying about 1/8" wide of the line.



Next, I screwed the panel down to prepare to route the panel to size. I am not worried about leaving holes in the jukebox because the material will eventually be removed.



After the piece was secured in place I used my router and flush cutting bit to make the 1/2" MDF panel exactly the right size.



Finally, I removed the newly cut panel.



Next up is laying out the hole openings for the marquee, monitor and speakers.

[mountain]

The cops have been notified! 

Looking great javeryh! You are documenting some steps that I left out due to the tight schedule I was on. What do you plan to use for the face and sides?

[javeryh]

The cops have been notified! 

Looking great javeryh! You are documenting some steps that I left out due to the tight schedule I was on. What do you plan to use for the face and sides?

Thanks mountain!  I have been looking for some laminate for the back panel and sides/curve but I haven't found any so far.  I have seen a sample of Wilsonart Black 1595-60 but it seems fairly rigid.  I'm not convinced it will bend like I want it to.  I was thinking it would come rolled in a tube but it just doesn't seem possible unless it comes in something 1/2 as thick.

I've struck out at 3 different Home Depots so far and the local lumber yard has to special order it ($45/sheet).  I have a few calls to countertop companies but they all have to place special orders. 

As for the front face, I'm already in the process of cutting this out of 1/8" black plexiglass.  I have easily put in about 20 hours now working on that front panel and I don't even have the monitor mounted.  It is an unbelievable amount of work.   The further I get into this project the more I am amazed at what you did in such a short period of time.  I was thinking this would be a quick little project to bang out in between arcade cabinets!  Boy was I wrong... 

[Kaytrim]

Laminate can be bent.  You just have to apply a little heat.  I used to work in a cabinet shop an whenever they had to bend the laminate around a curve they used a heat gun.  The key is to distribute the heat evenly across the width.  Keep the heat gun moving across the width while pressure is being applied for the bend.  When the laminate gets warm enough it will bend and not scorch.  You will scorch the laminate if you leave the heat gun on a single spot though.  This is a two person job, one to use the heat gun and the other to bend the laminate.

TTFN and Good Luck,
Kaytrim

[mountain]

I used the vertical grade stuff which is much thinner and bends really easily.

[javeryh]

I used the vertical grade stuff which is much thinner and bends really easily.

Thanks.  I looked up some Formica Laminate online and they say Home Depot is a distributor.  I am going to order a sheet of Formica® Brand Laminate >  Series >  Solid Colors > 909 Black (Matte).  I'm probably going to get 20 Grade.  Here is the description from their site:

Grade 20 Vertical Postforming Grade (VGP, Nominal Thickness .028" (0.7mm))
Outside and inside radii to 3/8" (9.5mm). A forming grade designed for vertical or light duty horizontal interior applications requiring radiused edges. Thinner than Grade 12; excellent for postformed radii. Installed panel width not to exceed 24" (609.6mm) maximum.

Unfortunately, it only comes in a 4'x8' sheet but at least I'll have a bunch left over for the next project!  They do make a 12 Grade which I could order a bit less of but it doesn't sound like it will bend as easy even though it is only .011" (0.3mm) thicker!

Grade 12 Horizontal Postforming Grade (HGP, Nominal Thickness .039" (1.0mm))
Postformable to permit bending on suitable commercial postforming equipment. Use whenever forming is desired for decorative or functional purposes in interior applications. Optimum postforming temperature is 325°F (163°C). Note: When used with a polished finish, Grade 12 is recommended only for light duty horizontal applications.

[Neilyboy]

lookin real good man.. I am jealous!!! keep up the good work and keep the pictures coming.

neil

[javeryh]

lookin real good man.. I am jealous!!! keep up the good work and keep the pictures coming.

neil

Thanks neil!  I was JUST looking at your DK restore (again - awesome job) and I'm 99.9% positive that will be my next project after the jukebox.   

[Nvts]

Keep the pictures coming.    I have a fairly good idea of how I wanted to make my version of Mountains box, and looking at this, your version and mine might just be identical.    I'm not woodworking-ly inclined, so all of your extra pictures are helping immensely.

[javeryh]

Keep the pictures coming.    I have a fairly good idea of how I wanted to make my version of Mountains box, and looking at this, your version and mine might just be identical.    I'm not woodworking-ly inclined, so all of your extra pictures are helping immensely.

Awesome - the more people building these things the better so we can help each other out.


OK - this is kind of what I've got going on right now.  It is an EXTREMELY tight fit to get everything in behind the panel.  The semi-circle in the middle of the marquee area that is not getting cut out is where the volume knob will go - just like mountain's.  I don't have exact dimensions written down anywhere - I'm just sort of eyeballing it - but this gives you an idea of the general layout.



The usable touchscreen area of the monitor is 11-15/16" wide by 8-15/16" tall. The 11-15/16" dimension will define the width of the side borders which will be 2-1/32" wide each (the width of the panel is 16"). After laying out the side borders I had to decide how thick I want the borders to be on top of the curve, between the marquee and monitor, between the monitor and speakers and between the speakers and the bottom edge to make the overall layout pleasing to the eye.  I also wanted to make sure that the ends of the marquee were in line with the sides of the monitor and speakers.

Stay tuned...   

[DaOld Man]

Looking good JH!
Your outline looks remarkably like my Stevies Jukebox, but I used a much bigger speaker area, plus I designed it so it would be wheel chair accessible, so it is taller than yours.

I appreciate you supplying all the measurements.
I now have a juke for the wife on the front burner and your measurements may save me loads of time.
But I think mine will have the rotating base, so it will be more a rip off of Mountains.
I think it would be very hard to top his design, so imitating it will be good enough for me.
And I showed my wife a picture of mountains juke and she fell in love with it.
(Maybe I shouldn't have done that???)

[javeryh]

Thanks DaOldMan!  Oh yeah - I'd be happy to try out your remote management software but I won't be able to until I buy a wireless card and install it into Bella's Arcade.... which probably won't happen for a while.  You can send it to me at javeryh@yahoo.com if you want.  It is something I really want to do because after a few months of play the gamelists definitely need some management but it is a huge pain to drag out the keyboard and mouse - plus it's uncomfortable.   

[javeryh]

Now we are getting somewhere!



The next thing I decided to do while thinking about the final layout of the front panel was to remove most of the material in the jukebox leaving only the shell. I used my circle cutting jig to cut out the arcs on the top of both the front and back panels. I also unscrewed the bottom panel and the interior spacers. It probably weighs less than a quarter of what it did before (it's light!). These pictures just show the rough cuts with the jigsaw - I will post "clean" pics when I get a chance. 

Here are a ton of pictures for no good reason:













I did have a concern about whether the shape would hold once all of the material was removed but it does not seem to be an issue.   

[javeryh]

Nothing major to report - Here are some shots of the cleaned up shell.  I used my router, a straight edge and a pattern bit to make the edges straight. I used a Japanese hand saw to square up the corners. The whole process took less than an hour.







Now the shell is complete the next step was cutting that front panel out - which is a HUGE PAIN - and squeezing everything inside.  I'm about 75% done with it right now and it has taken at least 20 hours for just the one panel.  I work slow though.

I still haven't ordered the computer parts yet mainly because I don't know what will be adequate.  I want to have between a 300GB and 500GB hard drive in there but other than that I have no idea what to get.  Since it will only play music and a few casual games it doesn't have to be powerful and I'd like to keep it on the cheap side.  I need a motherboard, some RAM, a power supply, a HDD and probably an internet card.  Any suggestions would be very helpful.   

[Nvts]

I checked Craigslist every day for a couple weeks watching prices, then picked up a 2Ghz machine for under $100.  I will throw a 640G drive in it, and I should be set.  I would expect a Mac Mini would work great.

[DaOld Man]

I found this deal on ebay:

Click

It is a complete dell optiplex, just strip what you need.

Im going to use a dell optiplex 260 for my upcoming juke. Ive got it laid out on the mad scientist slab right now. I think it is 2.4 gig P4 and it came with 512 meg DDR ram.
It is working very sweetly, running Xlobby like a champ.
I had to buy a power supply, cpu fan, and hard drive though. The above deal will already have all that, except you may want to add more ram.
If you are constrained on the room, you may want to go with a mini itx board (not real cheap).
If you want the measurements of the optiplex board just let me know.

[javeryh]

Thanks for the suggestions.  It is kind of tight in there so I was thinking of getting a mini-itx board.  I am getting frustrated with the amount of time it is taking me to manufacture the front panel.  I can't believe how fast mountain cranked his out.  I only get about an hour a night to work on it though so it's hard to make any real progress and now that the new TV season is starting the wife is going to want to actually spend time together so there will be even less time out in the garage.

My goal this week was to have the front panel completely finished and glued to the shell but I still have a lot to do.
- remove material behind monitor opening to mount monitor flush
- remove material behind volume knob
- remove material around top of volume knob
- cut speaker grill and install
- cut speaker fabric/material and install behind grill.  I still have to buy the speaker fabric/material - anyone know of a place?  I only need a tiny bit.
- cut marquee pattern out of 1/4" MDF

I'm a bit nervous to use my foerstner bit to remove the material behind volume knob so the guts of the powermate has a place to sit.  I don't want to go through the Plexiglas on the front side!  I also have no idea how to drill a hole through the Plexiglas for the volume knob.  Every time I've tried drilling through the Plexiglas it chips - the only router bit I have for the job is a 1/4" bit which isn't quite big enough... I'm sure I'll think of something...   

[ratzz]

Looks great so far Javeryh, what speakers are you putting in? Would be nice to stick a couple of Bose speakers in there!! 

[javeryh]

Looks great so far Javeryh, what speakers are you putting in? Would be nice to stick a couple of Bose speakers in there!! 

Thanks ratzz.  I'm not 100% sure about the speakers yet but I am leaning towards the Dell speaker bar that mountain used on his.  Do they make Bose speakers that small?  I've got about 2.5" of height to play with...   

[Kaytrim]

For drilling out the plexi I have used forstner bits and spade bits with hardly any problems.  On the spade bits make sure you get the ones with teeth on the ends.  Use a piece of scrap wood behind the plexi, don't use any pressure on the drill and let the bit sorta melt it's way through.  You can then clean up the edge with a small round file cutting at about 45*.

[javeryh]

For drilling out the plexi I have used forstner bits and spade bits with hardly any problems.  On the spade bits make sure you get the ones with teeth on the ends.  Use a piece of scrap wood behind the plexi, don't use any pressure on the drill and let the bit sorta melt it's way through.  You can then clean up the edge with a small round file cutting at about 45*.

Hmm... maybe I'm just applying too much pressure.  There was definitely no melting involved the last time I tried!   Tonight I'm going to try and knock off the first three things on the list above even if it kills me... or rather even if my neighbors want to kill me for using the power tools past 10PM. 

[ratzz]

Looks great so far Javeryh, what speakers are you putting in? Would be nice to stick a couple of Bose speakers in there!! 

Thanks ratzz.  I'm not 100% sure about the speakers yet but I am leaning towards the Dell speaker bar that mountain used on his.  Do they make Bose speakers that small?  I've got about 2.5" of height to play with...   

They have some here: http://www.bose.co.uk/GB/en/home-entertainment/personal-audio/computer-speakers/index.jsp but boy are those things expensive -- they sound unbelievable though!

Good luck with the rest of the build, I'll be following this one! 

[Kaytrim]

Hmm... maybe I'm just applying too much pressure.  There was definitely no melting involved the last time I tried! 

Applying too much pressure will crack the plexi every time.  Practice on some scrap plexi before you commit to the actual piece.

[mountain]

When I need a hole in plexi that is under 1/2" I always use my unibit. It is single fluted so it basically shaves the material from the inside of the existing hole. I have never had plexi crack using this method.

Here is a picture