After a few weeks of inactivity on this project it's time to get back to work! I didn't finish what I set out to do in Week 2 since I ended up making the circle cutting jig instead of actually cutting out the front panel. I hope this week is a bit more productive. The steps for Week 3 are as follows:
Hollow Out Shell
- unscrew bottom panel and interior spacers
- using the circle jig, remove material on front and back
- clean up lines with router and pattern bit
Finalize Front Panel Layout
- screen measurement (11-15/16" wide by 8-15/16" tall)
- volume knob measurement (1-11/16" diameter)
- remember to leave room for mounting brackets behind panel
- remember to provide for 1/8" lip for speaker grill behind panel
Cut Out Front Panel
- use 1/4" cutting bit with plunge router base for starter holes
- remember to punch pilot holes first
- use flush bit and straight edge for clean-up
Cut Out Plexiglass Panel
- glue black plexiglass to front panel template
- using the front panel template panel as a guide, cut out black plexiglass to size with router
- add 45 degree bevel to inside edges with router
This is actually quite a lot of work even though it doesn't seem like it so I will be very happy if I can get this stuff done this week.
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