Step 9: Component installation
To assemble the side panels, you'll need to find the center and screw on the first stick. Make sure it's vertical, because this is where the rest will be positioned from. To correctly space the sticks, I made 2 spacers by taping a 3/8 inch stack of pennies together and then clamped the next stick in place. Now you can screw through the holes in the perf, but make sure they're positioned away from where the sides will touch the side shelves and bottom part. When you get to the bends in the metal, you'll probably need to plane off the corners of the sticks to make them fit correctly. The speakers are just screwed through the same perf holes and into the sticks.
Cut a slot in the front where you want the disc drive and front control panel. Make the slot so that the slim drive fits snugly and then use a dead CD to help position the control panel. Make sure the CD doesn't rub on the edges of the slot so you don't scratch up all your discs. Mark the position of the buttons, knob, LCD, and bolt holes and then drill. Now you can bolt on the front control plate. To connect the knob to my amplifier, I crushed the aluminum tube axle a bit and then pushed it over the amp's knurled axle. There is a layer of felt on the back of the knob to keep the aluminum surfaces from grinding.
The way I built the main control panel was probably not the best, but I didn't want to have bolt heads interrupting the clean metal face, so I epoxied the joystick and trackball in place. You'll also want to put a strip of felt on the top edge of the front assembly, where the panel rests on the body.
The last step is to punch a hole in the bottom large enough to pass the power strips cord through. The only part I'm skipping over is the shelf I installed inside to hold my amplifier, which is way too hardware specific to cover here.