I built this Apple Watch and iPhone charging station for my friend. We used black walnut and UHMW plastic. It turned out better than expected!
Step 1: Cut Pieces to Size
I ripped the walnut on the bandsaw and cut the UHMW plastic (ultra high molecular weight polyethylene) to size on the table saw. We wanted it to have a layered effect with 1/2" walnut on the bottom, 1/2" plastic center, and 1/4" top plate.
Step 2: Cut Phone Slot
I used the scroll saw set to 18 degrees to cut the slot for the iPhone. A sharp chisel cleaned up the edges.
Step 3: Finished Base
I cut a 15 degree bevel on the front face of the base. I also cut a cavity in the bottom to hide the cords and add LEDs to light up the plastic.
Step 4: Trip to the Emergency Room
I was cutting a piece to small on the table saw and it kicked back at my face. I sliced through my nose requiring 11 stitches. I should have used the bandsaw to cut a piece that small. I've learned my lesson! Video above for those that are interested how it happened.
Step 5: Watch Stand
Using the UHMW plastic, I cut a half-moon shape and used a forstner bit to drill a circle on the face to hold the magnet charger for the Apple Watch. I cut a slit in the front of the watch stand to run the cable. It was held in place with a dab of super glue.
Step 6: Spray Lacquer
After taping off the charger magnet and holder, the dock was sprayed with 3 coats of satin spray lacquer.
Step 7: Finished Charging Station
Overall this project turned out to be one of my best. It looks and feels solid and professional. The phone and watch slide into place and charge with a nice positive click.
Step 8: Light Up Base
Next week I'm going to install white LEDs into the base so the plastic glows when plugged in. Here was a little test we did with a flashlight.
Step 9: A Reminder...
We used the piece that kicked back and hit my face in the finished product. It's a nice reminder to always wear eye protection!