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Step 6Assemble the Giant Lite Brite
Once the glue was dry and the santoprene was held in place I began to assemble the Lite Brite. First, Billy and I painted the plywood black - so it would look a little sleeker, and then we test fit the whole thing together.
Start by fitting the four panels around the back board. The backer board should slide right into the groove which you cut for it using the table saw. If it doesn't widen the groove by passing it through the table saw again, or spray some silicone into the groove to help it slide along.
Then, stack the two clear acrylic sheets on top of each other, putting the one with the holes on top, and slide them together into the middle 1/4" grove that you cut out for them in the plywood.
Before the final front panel could be slid into place I realized that I would need another set of supports to bridge the 1" gap between the two clear acrylic sheets and the black front sheet. 1" bolts weren't the most obvious choice, but they turned out to work really well.
I drilled through the two layers of clear acrylic, slid the bolt through from the back, held it in place with a nut, and repeated the process a few times spaced periodically throughout the entire sheet. The front sheet would rest on the bolts secured to the second set of acrylic sheets, which in turn would rest on the wooden supports that were affixed to the backer boards.
Before we sealed up the last side of the case, I turned everything on and made sure that everything worked properly. After giving it the final check, I slid the last panel into place on the side and used plenty of wood screws at each corner to hold the whole thing together.
The Lite Brite was outfitted with eye hooks so that we could secure it easily to a table or sawhorses when we bring it events like Yuri's Night and The Maker Faire. This step is completely optional of course.
Start by fitting the four panels around the back board. The backer board should slide right into the groove which you cut for it using the table saw. If it doesn't widen the groove by passing it through the table saw again, or spray some silicone into the groove to help it slide along.
Then, stack the two clear acrylic sheets on top of each other, putting the one with the holes on top, and slide them together into the middle 1/4" grove that you cut out for them in the plywood.
Before the final front panel could be slid into place I realized that I would need another set of supports to bridge the 1" gap between the two clear acrylic sheets and the black front sheet. 1" bolts weren't the most obvious choice, but they turned out to work really well.
I drilled through the two layers of clear acrylic, slid the bolt through from the back, held it in place with a nut, and repeated the process a few times spaced periodically throughout the entire sheet. The front sheet would rest on the bolts secured to the second set of acrylic sheets, which in turn would rest on the wooden supports that were affixed to the backer boards.
Before we sealed up the last side of the case, I turned everything on and made sure that everything worked properly. After giving it the final check, I slid the last panel into place on the side and used plenty of wood screws at each corner to hold the whole thing together.
The Lite Brite was outfitted with eye hooks so that we could secure it easily to a table or sawhorses when we bring it events like Yuri's Night and The Maker Faire. This step is completely optional of course.
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