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Step 8Metal
I used my cordless circular saw to cut the perforated aluminum sheet in half and some 2 1/4" black steel gas pipe clamped to a table to bend it to match the radii on the shelf and bottom parts. Positioning the bends the correct distance apart is pretty important - one end should just touch the front side and then once the 2 bends are made, you can trim off the excess on the back side. The perforated sheet's top and bottom edges have a small border with no perforation - position this on top.
You can use some heavy card to make templates of the screen surround pieces and then cut them out on the band-saw. the corners of these pieces are mitered an then force fit into place.
Use the circular saw or band-saw to cut out the 2 control plates. For the upper game control plate, choose the number of buttons you think you'll need and cut them on the drill press. I used a paddle bit for the 1 1/4 inch game buttons, but that was pretty nasty. Using the circle cutter was just as bad, but try using some lubricant to cool the metal and keep the cutters from sticking. I used the circle cutter only to cut the track ball, and ring holes. The outside of the ring was cut out on the band-saw. All the other holes are done with traditional twist drills. The most difficult part of shaping the aluminum is cutting the disc slot. I masked off the area with lots of masking tape to protect the surface in case my hand slipped and then cut the slot with a dremmel cut off wheel. I then cleaned up the slot and other holes with a metal file.
The knob is made by squaring up the ends of the rod with a file or disc sander. Centering the axle of the knob is extremely difficult without a lathe, but I got as close as I could and then trimmed the existing edges of the knob on the sander to make it concentric. With the axle (3/8 inch aluminum tube) installed I mounted the knob in the drill press and held the metal file against the corner to grind the chamfer. Then I notched out the hash marks with a file.
Neaten up the edges so you won't cut yourself on anything and get the faces to the point where you're happy with how they look. Glue the ring to the front plate with epoxy or super glue, using the knob to help center it. To keep dirt and fingerprints off the raw aluminum, coat them with clear lacquer spray. Coat the perforated sides with black primer spray.
You can use some heavy card to make templates of the screen surround pieces and then cut them out on the band-saw. the corners of these pieces are mitered an then force fit into place.
Use the circular saw or band-saw to cut out the 2 control plates. For the upper game control plate, choose the number of buttons you think you'll need and cut them on the drill press. I used a paddle bit for the 1 1/4 inch game buttons, but that was pretty nasty. Using the circle cutter was just as bad, but try using some lubricant to cool the metal and keep the cutters from sticking. I used the circle cutter only to cut the track ball, and ring holes. The outside of the ring was cut out on the band-saw. All the other holes are done with traditional twist drills. The most difficult part of shaping the aluminum is cutting the disc slot. I masked off the area with lots of masking tape to protect the surface in case my hand slipped and then cut the slot with a dremmel cut off wheel. I then cleaned up the slot and other holes with a metal file.
The knob is made by squaring up the ends of the rod with a file or disc sander. Centering the axle of the knob is extremely difficult without a lathe, but I got as close as I could and then trimmed the existing edges of the knob on the sander to make it concentric. With the axle (3/8 inch aluminum tube) installed I mounted the knob in the drill press and held the metal file against the corner to grind the chamfer. Then I notched out the hash marks with a file.
Neaten up the edges so you won't cut yourself on anything and get the faces to the point where you're happy with how they look. Glue the ring to the front plate with epoxy or super glue, using the knob to help center it. To keep dirt and fingerprints off the raw aluminum, coat them with clear lacquer spray. Coat the perforated sides with black primer spray.
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Aug 24, 2009. 5:07 PMronmaggi
says:
For good cabinet quality clean holes, use forsner bits. They can be found at Rockler.
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