ValveLiTzer Trifecta

Step 3 Cut out the Wood and Plastic Patterns

I use a DeWalt DW788 variable speed scroll saw. It's really fantastic. But enough about my favourite tool in the workshop.

The easiest piece to cut is the base. Simply cut around the outside line, ignoring all the extra lines that show where the metal plates and components go.

To make things easier, the main case is cut in two parts. Start by cutting out the holes where the in and out jacks and the power jack will go, from the 3/4" plywood. Don't cut anything else. Next, glue the 1/4" plywood to the bottom of the 3/4" piece, being mindful not to get any glue on the cutouts. Clamp the pieces together no minimize any visible seam.

When the glue is dry, drill a pilot hole for the interior cuts. Then carefully cut out the inside and outside edges of the main frame. Take note of where the aluminum pieces will be, and cut out the notches for them. Also be aware of the support pieces on either side of the switch.

Cut out the top panel bezel carefully. Do the outside first, then drill a pilot hole and do the inside cuts.

Finally, install the crown tip blade into the scroll saw and turn the speed down to about 1/4 (setting 3 on the DeWalt 788). This will allow you to cut the plastic without melting it. Cut around the very inside lines. The plastic piece should fit perfectly inside the wood bezel. Finish the plastic piece by drilling 3/32" pilot holes for the switch and two adjustment knobs.

Comments

[asdterror]

Delicate work! Well done:)

[asdterror]

Well-written, great techniques! Several new tricks for the toolbox. Thank you.

[jeff-o]

Thanks! That's usually my goal for any project; to implement new techniques that I've dreamt up!