Step 4: Build Pt. 1 - Cutting Wood
..No, it's not technically wood that I am using. It's MDF, as stated in the previous step. MDF stands for "Medium Density Fiberboard". I had been wanting to see what it was like to work with MDF for a while, because in a lot of cases it can be more durable than wood. This was also very easy to cut and work with. I used mainly the jigsaw and oscillating cutter for this step.
(*7/23/2012: tafelice and isaacwilk were nice enough to p oint out that MDF has the tendency to absorb moisture easily, which I didn't know when I began this build. It's a good idea to make sure you coat the Unit with a clear coat, or paint of some sort once it's built to try to minimize this.)
I began by cutting my largest shape. In this case I had to try to match the shape of my car window. I did this by measuring the general dimensions of the window, and gradually cutting down the edges and adjusting the curve to match as best I could. it's not perfect, but it fit somewhat nicely. I'll refer to this as the "base board".
After knowing how big my window was, I was able to identify how large the outer box of the Unit could be. I marked this on the base board, and measured to cut for sides of my box, and thin strips for the top of the box, where the glass would be mounted later. Notches were cut out of all the pieces so that they would fit together nicely to be glued together.
There's not too much I can do to describe this step. It was a lot of tedious measuring and cutting, as I made it up as I went along.