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Step 4Building the Awesome!
Awesome! Now that we're done we've got the scale paper model, it's time to begin copying it to it's plexiglass frame!
First, place the rescaled papercraft model on the 1/16'' plexiglass and trace the rectangular outline, using a square-edge ruler and a fine tip sharpie marker. Then, using a hacksaw, cut out each of the individual pieces making sure that the pieces are as straight as possible, using the metal vice to keep them in place. Once all the parts are cut out, use the metal wood file to keep the edges flat and straight. Once that's done, use your Dremel Tool and drill the side holes for the speakers.
Then, when you've got all of the pieces cut out in plexiglass, we can begin gluing them together using the Acrylic Cement. A word of advice: this stuff dries fast, so make sure that the pieces are perfectly perpendicular before applying the cement. To make mine straight, I placed the two parts against a flat edge 90 degree surface like a corner between a paper cutter and a table. Then, use the epoxy glue to fill any necessary gaps.
Also important, keep the backside unglued! This is how we will be putting in all the electronics for later.
Editor's Note: I decided to use plexiglass over some easier to cut/ file material like wood because I didn't want to have to glue in a separate piece for the screen. The body and screen are completely connected together if you use plexiglass, it's just a matter of isolating which places to paint. Also for the Electronic Fan, remember when building the body to cut out a small hole in the bottom for the controller.
Also, I'm really really sorry for the blurriness of these pictures. They seemed better when I took them.
First, place the rescaled papercraft model on the 1/16'' plexiglass and trace the rectangular outline, using a square-edge ruler and a fine tip sharpie marker. Then, using a hacksaw, cut out each of the individual pieces making sure that the pieces are as straight as possible, using the metal vice to keep them in place. Once all the parts are cut out, use the metal wood file to keep the edges flat and straight. Once that's done, use your Dremel Tool and drill the side holes for the speakers.
Then, when you've got all of the pieces cut out in plexiglass, we can begin gluing them together using the Acrylic Cement. A word of advice: this stuff dries fast, so make sure that the pieces are perfectly perpendicular before applying the cement. To make mine straight, I placed the two parts against a flat edge 90 degree surface like a corner between a paper cutter and a table. Then, use the epoxy glue to fill any necessary gaps.
Also important, keep the backside unglued! This is how we will be putting in all the electronics for later.
Editor's Note: I decided to use plexiglass over some easier to cut/ file material like wood because I didn't want to have to glue in a separate piece for the screen. The body and screen are completely connected together if you use plexiglass, it's just a matter of isolating which places to paint. Also for the Electronic Fan, remember when building the body to cut out a small hole in the bottom for the controller.
Also, I'm really really sorry for the blurriness of these pictures. They seemed better when I took them.
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