The Back Panel III

More progress! After getting the 1/8" MDF laminated and rough cut to size I didn't think there was any way that it would turn out nice considering it was chipped and there was glue everywhere. The next step was cutting the panel to its proper size with my router and flush cutting bit.

First, I put some double sided tape around the perimeter of the jukebox shell:

Then, I carefully placed the rough panel on top of the tape making sure that when the overhanging material was removed that there wouldn't be any chip marks showing. The clamps were for added support although they definitely weren't needed - the double stick tape is pretty strong:

Next, I just went around the outside with the router and ended up with the exact shape I wanted! After I had the proper shape, I used a template I had made way back in the beginning of the project for the front panel to cut out the opening for the vent on the top of the back panel (I used double stick tape again). It was easy - the router cuts through the laminate like butter!

You can still see the glob of glue on top that would have to be removed. After that was finished the last thing I did for the night was drill out the hole for the power button in the center of the small semi-circle. I used my step drill bit and widened the hole to 3/4" diameter.

The button looks great and should match the other aluminum accents on the jukebox (speaker grill, t-molding, etc.). Oh, yeah - I was able to remove the glue using my fingers quite easily. I just rubbed it until it came off from the friction. Check it out (don't mind the dust):

Next up for the back panel is cutting the hole for the I/O panel along the bottom which will mirror the speaker grill on the front panel. Then I will install magnets on the inside so the panel will stay in place but remain removable in case I need to get in there for maintenance.

More later!