Introduction: Amplifier Dock
Step 1: Materials and Tools
Hard wood at least .38" x 2.50" x 10.00"
A Bowl roughly 6.25" in diameter and 2.50" height
A small cut of 1/8" thick wool felt
Wood Working tools
Wood planer (if material is not already to .38" thickness)
Miter saw (or hand saw)
Belt or disc sander
3/16" Drill bit, 1/4" Drill bit, 3/4" Forstner bit, Countersink bit
Tape measure and Square
Medium and Fine grit Sandpaper
Step 2: Plane Hardwood to .38" Thickness
The hardwood portion of the dock is comprised of three parts, all of which are the same thickness.
First order of business: plane hardwood to .38".
Step 3: Cut to 2.31" Width
Next, use the table saw to cut your .38" piece to a 2.31" width (width of iPhone 4/5).
Keep a consistent speed while cutting to prevent burn marks like mine.
Step 4: Cut the Dock Into Its Components
Use the miter saw to cut your .38" x 2.31" piece into the three separate lengths measuring A) 6.00", B) 2.31", and C) 1.00". Make sure to account for blade thickness when measuring and cutting your pieces!
Reference the technical drawing (.jpeg and .pdf) for the remaining measurements and cuts.
Step 5: Prepare Base for Tee Nuts
Reference the technical drawing to measure out the holes on the bottom of the base. Next, grab the 3/4" fortsner bit and bore a shallow hole using the drill press. This step will allow the tee nuts to sit nice and flush on the bottom of the base.
Step 6: Drill Out the Base
You're ready to drill out the holes for the tee nuts to slot through. Use a .25" bit.
Step 7: Countersink and Drill 3/16" Hole
Being mindful of the end grain, take your three pieces and sandwich them together with some masking tape.
Mark points for the holes and using the countersink bit, carve out space for the flat head screws.
Next, grab the 3/16" bit and drill all the way through.
Step 8: Insert Tee Nuts
You're all set to make metal meet wood. Use a mallet or dead blow hammer insert the tee nuts.
Step 10: Round the Corners
It's coming together now!
Use the disc sander to round the corners to a .35" radius (radius of iPhone 4/5).
Step 11: Sand It Smooth
Use a medium and then fine grit sandpaper to get a nice smooth finish.
Step 12: Cut Wool Felt
The wool felt adds holding power to the dock by compressing and increasing the surface area in contact with the bowl. Use an X-acto knife with a sharp blade to cut out a rounded 2.3" square from the 1/8" thick wool felt.
Step 13: Glue Wool Felt to Cap
Use craft glue to attach your rounded wool felt square to the bottom of the cap.
Step 14: Poke
Use an awl, or similarly pointy thing to poke holes through the wool from the cap.