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Step 6Making the case
The case is made of 1/2" think by 6" wide boards, I am using Poplar on mine as it is cheap and accepts stain well.
To make the case you well need:
1 x 1/2"x6"x4' long board
1 x 3/8"x6"x2' long board
- glue
- nails
- finishing supplies, paint, stain, whatever
Tools:
- Saw, I am using a power miter box because I am lazy
- Hammer, again I am lazy so I am using a pneumatic brad nailer with 1" long brads
- Sanding block and sand paper, I use 220 because it well wear down to finer and finer grades as you use it so it leaves a nice surface for finishing.
1) The first thing that has to be done is to cut the boards to length to make the sides and front and back. You well need to cut 2 1/2"x6"x9" long boards for the front and back and 2 1/2"x6"x7" long boards for the two sides, also cut 2 3/8"x6"x7" long boards to be glued together for the bottom.
2) Next you need to glue the two sides and front and back together to make a box, the two side pieces go between the front and back not on the ends of the front and back.
3) Now would be a good time to use some wood putty to fill in the holes left by the nail set, or in my case the hammer of the pneumatic brad nailer.
4) To make the bottom you well need to glue the two 3/8" pieces that are cut to 7" long along the sides that are 7" long. Start by sticking a wide piece of masking tape, 1" is probably good enough, along the 7" long edge of one of the boards leaving it sticking out half way, see photo.
5) Butt the other piece of wood up to the first one and align the ends so that they are flush and stick the tape down to the other board while holding the two firmly together.
6) Once the tape is stuck to the other board flip the two over and fold them together so you can apply glue to the edges that well be stuck together.
7) Spread some glue to the edge of one of the boards where the seam well be and lay the two boards out flat again of a flat hard surface.
8) Push down along the seam to ensure that the two boards and even and all the excess glue squeezes out and wipe up the excess.
9) Put another piece of tape alone the seam on this side making sure that the seam is flat and even then place another board on top of the two being glued together and place a heavy weight on top of that to hold it down while it is drying.
10) After the glued has dried on the bottom, pull the tape off and trim it to length so that it fits inside of the bottom of the box and glue it in.
11) I also decided to make a lid for my prototype, I glued two boards together the same way as I did on the bottom and cut it to size so that it sets over the top of the box.
12) Next add some slats to the inside of the box to screw the panel to, if you are making a lid set the slats down 1" from the top, it not set them 1/8" from the top so that the panel well be flush with the top of the box.
13) Finish the box with what ever finish you desire, I chose to staining mine and then coating it with two coats if polyurethane, you could paint it instead which would be simpler.
14) Once the finish has had adequate time to dry, tape the top down to the top of the box in the orientation that is well be in when finished on the three sides that well not be hinged.
15) Using pieces of tape to hold the hinges in place, drill pilot holes for the hinge screws and install the lower screws. After the bottom half of the hinge is mounted pull the tape off and attach the upper half.
16) Remove the tape holding the top on and make sure the hinges do not bind.
To make the case you well need:
1 x 1/2"x6"x4' long board
1 x 3/8"x6"x2' long board
- glue
- nails
- finishing supplies, paint, stain, whatever
Tools:
- Saw, I am using a power miter box because I am lazy
- Hammer, again I am lazy so I am using a pneumatic brad nailer with 1" long brads
- Sanding block and sand paper, I use 220 because it well wear down to finer and finer grades as you use it so it leaves a nice surface for finishing.
1) The first thing that has to be done is to cut the boards to length to make the sides and front and back. You well need to cut 2 1/2"x6"x9" long boards for the front and back and 2 1/2"x6"x7" long boards for the two sides, also cut 2 3/8"x6"x7" long boards to be glued together for the bottom.
2) Next you need to glue the two sides and front and back together to make a box, the two side pieces go between the front and back not on the ends of the front and back.
3) Now would be a good time to use some wood putty to fill in the holes left by the nail set, or in my case the hammer of the pneumatic brad nailer.
4) To make the bottom you well need to glue the two 3/8" pieces that are cut to 7" long along the sides that are 7" long. Start by sticking a wide piece of masking tape, 1" is probably good enough, along the 7" long edge of one of the boards leaving it sticking out half way, see photo.
5) Butt the other piece of wood up to the first one and align the ends so that they are flush and stick the tape down to the other board while holding the two firmly together.
6) Once the tape is stuck to the other board flip the two over and fold them together so you can apply glue to the edges that well be stuck together.
7) Spread some glue to the edge of one of the boards where the seam well be and lay the two boards out flat again of a flat hard surface.
8) Push down along the seam to ensure that the two boards and even and all the excess glue squeezes out and wipe up the excess.
9) Put another piece of tape alone the seam on this side making sure that the seam is flat and even then place another board on top of the two being glued together and place a heavy weight on top of that to hold it down while it is drying.
10) After the glued has dried on the bottom, pull the tape off and trim it to length so that it fits inside of the bottom of the box and glue it in.
11) I also decided to make a lid for my prototype, I glued two boards together the same way as I did on the bottom and cut it to size so that it sets over the top of the box.
12) Next add some slats to the inside of the box to screw the panel to, if you are making a lid set the slats down 1" from the top, it not set them 1/8" from the top so that the panel well be flush with the top of the box.
13) Finish the box with what ever finish you desire, I chose to staining mine and then coating it with two coats if polyurethane, you could paint it instead which would be simpler.
14) Once the finish has had adequate time to dry, tape the top down to the top of the box in the orientation that is well be in when finished on the three sides that well not be hinged.
15) Using pieces of tape to hold the hinges in place, drill pilot holes for the hinge screws and install the lower screws. After the bottom half of the hinge is mounted pull the tape off and attach the upper half.
16) Remove the tape holding the top on and make sure the hinges do not bind.
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