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Step 3Cutting the plywood and aluminium sheets
The first thing is to mark out the plywood and aluminium sheets and cut them to size. The whole pad is 30cm square from edge to edge, and all the sheets need cutting to this size first. You will need a pad saw with a blade for cutting metal if you can't buy aluminium cut to size.
Next you need to cut a square hole in the top plywood sheet (the thinner sheet) to make a frame. I was using 35mm piezos (any smaller probably wouldn't work as the rubber would squash too much), and a gap of 5mm around these, making the width of the border of the top frame 45 mm. So the next step is to cut the top sheet into a frame with 45mm width left around each edge. To do this, mark out a line 45mm in from each edge, then drill large holes inside the corners of this square. Then use the padsaw with a wood cutting blade to cut out the central part.
You may want to sand the edges of the plywood sheets at this point to make it look neater.
Next you need to cut a square hole in the top plywood sheet (the thinner sheet) to make a frame. I was using 35mm piezos (any smaller probably wouldn't work as the rubber would squash too much), and a gap of 5mm around these, making the width of the border of the top frame 45 mm. So the next step is to cut the top sheet into a frame with 45mm width left around each edge. To do this, mark out a line 45mm in from each edge, then drill large holes inside the corners of this square. Then use the padsaw with a wood cutting blade to cut out the central part.
You may want to sand the edges of the plywood sheets at this point to make it look neater.
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