Page currently being written.
Tools and Materials:
- PVA Wood glue. We recommend Gorilla Wood Glue due to its long open work time and short clamping time. Other glues will work but you may have less time to align all the parts before the glue starts to set, and you may need to add five minutes to the clamp time.
- A dozen small clamps.
- Clothes pins or binder clips can be used.
- Four or more medium clamps.
- Four medium to large rubber bands.
- A dozen small clamps.
- Toothpick or scraper for removing glue from inside corners.
- Sanding block or palm/finish sanding machine.
- 80, 150, and 320 grit sanding paper for sanding block or machine.
- Stain, or wood dye, or paint, or lacquer.
- Other supplies may be required depending on finishing method.
Part I: Assembling the Case
The front of the outer panels has tape to protect the surface. Remove the tape but don’t lose track of which side is the outer facing side. The rear side may have pencil markings — if it doesn’t feel free to add them.
1. Inner Panels
Begin by gluing both inner side panels.
Each of the panels consists of an INNER SIDE and an OUTER SIDE.
Put a small amount of glue on the INNER SIDE panel and place over the OUTER SIDE panel, aligning the bottom of the INNER SIDE panel to the line across the bottom of the OUTER SIDE panel.
Make sure the INNER SIDE is aligned to the line marked on the OUTER SIDE, and the other sides are completely flush.
Clamps can be removed after 20 minutes. Glue will be dried but not cured to full hardness, which takes 24 hours. Part can still be used in other operations after 20 minutes.
2. Outer Case
Identify the inner sides of the outer case panels.
Add glue on each end of the two side panels as shown.
It is not necessary to add glue to the front and back panel.
3. Joining Inner Sides
Joining Inner Front and Back
Part II: Surface Finishing
Now is a good time to apply a finish for appearance and protection.
A quick, easy, and durable finish is simply a few coats of lacquer from a spray can. This will protect the surface and will be dry and ready for final assembly in a few hours. Check out this video.
Other finishing options are staining, dying, painting, etc.
Black stain, rubbed out Wood Dye (Purple) + Lacquer Stain (Mahogany) Black stain, rubbed out + Lacquer Wood Dye (Red) + Lacquer
Part III: Putting It All Together
Instructions for power PCB in a separate document (TBD: link).