Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 Time for some pictures of yesterdays progress. First, another tool gets the spotlight. My table saw is great but especially for this project because of the size of all the pieces (sides and internal parts) the slide saw makes it quick and easy. Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 I had a couple of tubes of PL that were opened so I thought I would use them up, but the PL likes to get a hard plug in the tube once you open them up if you don't use the whole tube, even if you try and cap the end so a simple solution is to just take a cheap drill bit and drill it out and it's all good. You will also notice the Kreg tool and I've said before that if you don't have one, then you need to put it on your list along with a good impact driver and a narrow crown stapler as they will make your projects go much smoother and faster. Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 Glued up and ready for the side to be installed. For those of you that have never used PL just know it's going to make a mess and you might as well stick your fingers in it first as it's going to happen at some point anyway.[] Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 First piece installed which is a combination of glue (PL), 1.25" narrow crown staples that I shot in from the bottom first to align the panel and then pocket screwed. Keep in mind that once the PL sets you could really remove all the fasteners and everything would be fine, the stuff really holds great. Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 Because the glue is so strong and I won't be putting the top on today I use some cut off pieces and a clamp to keep everything plumb as the glue is drying. Keep in mind with PL or any adhesive that expands as it cures you better clamp and secure it will or it will move your pieces. Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 I can't believe that nobody wants to know what I'm listening to while I work. Klipsch of course, currently running the RP 3's and a decent receiver, more than enough to really get it rocking in the shop. Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 While I'm doing projects like this I always have a cheap putty knife and some scrap wood close to the action so I can immediatly remove the excess adhesive and in this case, fill the pocket holes as I go. Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted January 1, 2012 Share Posted January 1, 2012 Kreg tool [Y][Y][Y] Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 I pointed the ends of the interior pieces, um becasue the point will stop the uhhhhhhh air vortex from, well, from getting confused when it goes around the corner, yea, that's it.[bs] OK, I just did it casue I could and it makes it mine, so I hope it doesn't hurt the design.[^o)] Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 All parts cut and maybe I'll get the access panel cut and the last 2 interior panels in today. Happy New Year to all![<)] Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 Here's one more interior piece installed and after scraping the PL with the knife to finish the joint I'm showing an alternative method of plugging the pocket screw holes. These are plugs that you can buy in plastic or wood and can simply be glued in place and then sanded off. Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 If you are going to use the excess PL to plug the voids as I described earlier you can take a simple razor scraper and cut off the excess when cured and then fill the small voids with wood filler or caulk and walk away. Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 Wood filler and done Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 Temporarily installed the long motor board panel to square up the last 2 interior pieces. I stapled the 2 braces you see on top and then removed the long motor board panel. Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 Time to cut out the exit port. Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 Set up to plunge cut with the skil saw, guide attached. I do not recommend this for anyone that hasn't used a circular saw a lot and done this before, but it's much quicker than using pilot holes and a jig saw. Normally I wouldn't even use a guide but I want the exterior cuts to be very clean so an extra minute to put the guild on was OK. Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 When the guide won't work then just a couple of quick measurements and a guide board and you're ready to go. Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 Plunge cuts made and jigsaw used to quickly clean out the corners. Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 Just to show how I used the guide to fasten interior panels since I've explained that I didn't route in any of the panels for this build. This was where I had already glued and pocket screwed the 2 interior panels that I didn't complete yesterday so when I installed the temp braces I flipped it over and put to clamps on and took the stapler and put an additional 5 or 6 staples in per run. Quote Link to comment Share on other sites More sharing options...
Pete H Posted January 1, 2012 Author Share Posted January 1, 2012 Now I used the router to do a little round over detail on the exit location. Quote Link to comment Share on other sites More sharing options...
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