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Step 4Cut the wood
Now that you have your template designed, its time to start cutting the wood. I started out cutting the key switch hole, since it was in the middle. I then moved on to the pushbutton switches, then the speaker terminals, and then the toggle switch and fuseholder holes. You can do it in whatever order you like.
One thing I do suggest is to cover the back with tape to prevent splintering of the wood since you are working with such thin material. I also drilled halfway through one side and then flipped it over to drill all the way through the other side to keep it from splintering even more.
After that you should drill the toggle switch and fuse holder holes (I didn't do this in order, don't know why not). I don't have the correct size drill bit, so I used the dremel to widen these holes to the correct size.
After you get those holes drilled, start cutting the slots for the speaker terminals. I used a drill to drill pilot holes at each end of the line, then a small saw to cut the wood in between them. The saw cut a wide enough line to slip the thin metal tabs of the speaker connectors through them. Use a dremel sanding bit to smooth out all the holes and cuts and get rid of rough edges and splinters.
After this you can test fit the components to make sure everything is lined up well and fits. Take everything back out when you are done, because there's more to do.
One thing I do suggest is to cover the back with tape to prevent splintering of the wood since you are working with such thin material. I also drilled halfway through one side and then flipped it over to drill all the way through the other side to keep it from splintering even more.
After that you should drill the toggle switch and fuse holder holes (I didn't do this in order, don't know why not). I don't have the correct size drill bit, so I used the dremel to widen these holes to the correct size.
After you get those holes drilled, start cutting the slots for the speaker terminals. I used a drill to drill pilot holes at each end of the line, then a small saw to cut the wood in between them. The saw cut a wide enough line to slip the thin metal tabs of the speaker connectors through them. Use a dremel sanding bit to smooth out all the holes and cuts and get rid of rough edges and splinters.
After this you can test fit the components to make sure everything is lined up well and fits. Take everything back out when you are done, because there's more to do.
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it is also from black&decker i can see their logo on yours!