pinewood derby display case - final[1] - cub...
TRANSCRIPT
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SAFETY–GOGGLES,PAINTERS/DUSTMASK
Front
FinishedInteriorDimensions
217/8”(H)
X9”(W)X
3”(D)
4”Heightbetweenshelves
ExteriorDimensions23½”(H)X10½”(W)X3½”(D)
Back OPTIONALDoor
Finishedinterior203/8”D
X7½”W
Finishedexterior23½”X101/2”
Routergroove¼”offbackedge-slightly
deeperthanthedado/routershelfcutstoallowforbackpanel
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SAFETY–GOGGLES,PAINTERS/DUSTMASK
MaterialsListMediumandfinesandpaper/sponge.Two12”woodclamps,woodglue.
CabinetFrame-LumberNominalSize1”X4”X72”ActualSize¾”X3½”X72”Shelf-LumberNominalSize½”X4”X48”ActualSize7/16”X3½”X48”
BackPanelNominal/ActualSize¼”X12”X30”(ConsiderMenards®SKU:4794561)
Notes:Thinkaboutthetypeofwoodyouwouldliketouse.Mahogany,oak,cherryandpinecouldbesomepopularchoices.Eachtypeofwoodhasitsowncharacteristics.Startthinkingabouthowyouwantyourfinishedproducttolookbeforeyoustartpurchasinglumber.Chooseboardsthatarenotwarped.Longerboardstendtohavemorewarptothem,inspectyourlumberwellbeforeyougototheregister.ThebackpanelcanbemadefromaplywoodveneerhoweverIfounditdifficulttofindapiecethatwas“clean”andendedupusingacabinetendpanel.Dependingonyourchoicesafinishedproductcanrangefrom$15-$35.
OptionalDoorDoorFrame-LumberNominal1”X2”X72”Actual¾”X1½”X72”
Plexiglas/Acrylic1/8”X12”X24”Note:Actualthicknesswillbearound0.118”.Smallsheetscanbehardtofind,andyoumayneedtobuyalargersheet.Hinges(non-mortice)&ScrewsManyhingechoicesareavailablebutconsiderRocklerpart#028670whichareverylowprofileandhelppreventdoorbinding.Four½”woodscrews&clasporhooktosecuredoorshut.
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EquipmentNeeded
NotnecessarybuthelpfulTablesawwithdadoblades(upto½”stackedbladesforwidecuts)(Youcanuseatable,miter,circularorhandsawfortheroughcuts.)
NecessaryRoutertablewith1/4”bitsforbackpanelgroove.NOTE:1/2”and3/8”routerbitsarerequiredifyouarenotusingtablesawdadoblades.OptionalDoorrequires1/8”routerbitandtablesawlaminatebladeorlaminaterazor(cuttingPlexiglas).
OrderofOperation/RoughCutsUseatable,circular,compoundorhandsaw.
Donotassumethefactoryendsarestraight–makeafresh/straight-cleancut.CabinetFrameUsingNominal1”X2”X72”–cuttwo23½”piecesandcuttwo10”pieces.
ShelvesUsingNominalSize½”X4”X48”-RIPboardreducingActualdepthfrom3½”to3”.Cutfour9½”pieces.Atablesawwillmakethiseasier.
BackPanelUsingNominal/ActualSize¼”X12”X30”cutdownto22½”X97/8”.
OptionalDoorFrameUsingNominal1”X2”X72”–cuttwopieces23½”(stile)andtwo10½”pieces(rail).Using1/8”X12”X24”Plexiglas/Acrylic-cuttoreduceto81/16”X211/16”.Note:besuretouseabladeorknifeapprovedforPlexiglas.
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DesignCutsCabinetFrameMakethefollowingcutsonboth23½”CabinetFrameSidePiecesusingatablesawwithadadobladeorrouter.
Notes• Thetopandbottomcutsaredifferentthantheothersinbothsizeand
depththantheothercuts.• Thepieceissymmetrical.Onceyouhaveyourtablesawdadobladeor
routertablesetupfortherightwidthanddepthyoucansimplyswingtheboardaroundtomakethesamecutontheopposingendANDotherboard.
• Makethesamecutsonbothpiecesbeforechangingbits/bladesordepth.• Remembermeasuretwiceandcutonce,beprecise.• Blowout(tearingofwoodfibers)canfrequentlyoccurwhencuttingacross
thegrainofthewood.Puttingapieceoftapeoverthebackofthecut(endofcut)canhelpreducetheseverityoftheblowout.Sandcutsclean.
Lookingattheleftcolumn,topcutbelow(seehighlight)“Dado½(D)X3/8(W)”meansusinga3/8dadostackor3/8routerbitwide(W)setat½”depth(D).
3/8”HDado½”(D)X3/8”(W)
4”1/4”(D)X½”(W)dado4”1/4”(D)X½”(W)dado4”1/4”(D)X½”(W)dado
4”1/4”(D)X½”(W)dado4”Dado½”(D)X3/8”(W)
3/8”H
3/8
3/4
43/4
51/4
91/4
93/4133/4
141/4
181/4183/4
223/4231/8
Markthenarrowedgeofyourboardswiththese12measurements.
Thesewillbeyourshallowcuts.
(SeePicture1)
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SAFETY–GOGGLES,PAINTERS/DUSTMASK
CabinetFramecont.Makethefollowingcutsforthetop&bottomofCabinetFrame-usinga½”tablesawdadobladeor½”routerbit.Takethetwo10”piecesandremove½”WX3/8”Dwideoffeachendofboard.Sandcutsclean.NOTE:Blowoutcanfrequentlyoccurwhencuttingacrossthegrainofthewood.Puttingapieceoftapeoverthebackofthecut(ENDOFCUT)canhelpreducetheseverityoftheblowout.
Router-GrooveforBackPanelAftercompletingallofthecutsaboveonallfourpiecesusearouter(table)andrunagroovedownonesideofeachboardwith¼”bitat½”depth,centeredat5/16”offbackedge(leave¼”offbackedge).NOTEitmightbeeasiertomakeseveralshallowpassesworkinguptoa½”depth.IMPORTANT:Donotrouterstartingorending3/8”ontheCabinetFramesidepieces-stopinthecutout.Optional:ifyouwouldliketohangyourdisplaycaseyoucanuseakeyholecutterrouterbitonthebackofbothpieces,setdepthofcut¼”.BesuretocutattheexactsamelocationonbothCabinetFramesidepieces.
Top&BottomFramepiecesCutgrooveonsidew/ocutouts
Stop
SidepiecesGrooveonsidewithcuts(SeePicture1and2)
SeePicture2
SeePicture3
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SAFETY–GOGGLES,PAINTERS/DUSTMASK
CabinetFramecont.ONLYifyouarebuildingtheOptionalDoor-thedoorframewillobscurepartofthePWDcaronthelowestshelf.Tocorrecthisyoucanaddariserusinga7”remnantofthe1”X2”lumberfromthedoorframe.
CabinetFrameAssembly
Viewfromside
ScrewtherisertotheCabinetFramebottom
piecewithtwo1¼”woodscrews.Centerlefttorightandfronttobackofgroove.
Center
Groove________Viewfrom
top
AddwoodgluetoallFOURFRAMEcorners-clampuntilgluesets.
SlideBackPanel
intogroove
SeePicture4
SeePicture5-8
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SAFETY–GOGGLES,PAINTERS/DUSTMASK
OPTIONAL:CabinetDoor-Cuts
Usepiecesmentionedonpage4-OrderofOperation/RoughCuts-two23½”(stile)andtwo10½”pieces(rail).Topreventblowouttapeendofcut.Remove1½”X1½”X3/8”Doffeachendonall4pieces(8cutsintotal)tocreatelapjoint.Todothisyoumayneedtomakeseveralpassesonyourtablesawwithdadobladeorroutertable.Tokeepyourcutsuniform,passeachside-ofeachpiecethruyoursaworrouterbeforemovingthefenceforthenextcut.
Sandcleanwhenyouarefinishedwithall8endcuts.Usingaroutercreateagroovedowncenterofall4pieceswith1/8”bit-¼”D.Donotroutergrooveinstartingorending1”ofboard(youwillmakeapartialcutintothelapjoint).Thiscreatesthegapfortheplexiglass.
Stop SeePicture9
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OPTIONAL:CabinetDoor-Assembly
Notegroovesonboards.Addgluetostilelapjoint.
Screwlapjointofrailandstiletogether(slightlycountersink).
SlidePlexiglasintogroove.
Addgluetostilelapjoint,secureadditionalrailwithscrew.
Rail
Stile
Glue
Recessfacedown--------------------------
Recessfaceup
Screw
Plexiglas
Screw Glue
Screw
SeePicture10-12
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SAFETY–GOGGLES,PAINTERS/DUSTMASK
Glue
OPTIONAL:CabinetDoor–AssemblyCont.
Addgluetobothendsofstile,slidestileunderrailsandintoPlexiglas.Screwtogetherandclampuntilgluesets.
Installhinges.Considerpredrillinghingeholes,thesescrewstendtobeverysmallandbreakeasily.Iftheunitisnotwallhung,considerraisingthedoora1/16”offthebottomofthecabinetsothatitcanbeeasilyopenedwhilesittingonaflatsurface.
PlexiglasPlexiglas
Completedbackofdoor
Hingeholes
SeePicture10-12
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SAFETY–GOGGLES,PAINTERS/DUSTMASK
Stainorpainttomatchyourtaste.IfyouwouldliketoleaveitnaturalIdosuggestavarnishorpolytopreventlongtermwarping.Installknob–considerusingaPinewoodDerbywheelandaxel.InstallClasptoholddoorshut.
LoadwithyourPinewoodDerbycarsandenjoyyourPinewoodDerbydisplaycase!
Iwouldlovetoseeyourcompleteddisplay–[email protected]
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SAFETY–GOGGLES,PAINTERS/DUSTMASK
Picture1–CabinetFramesidepieces-Shownwithframecutouts,shelfcutoutsand
routergrooveforbackpanel.
Picture2-CabinetFrametopandbottom–shownwithframecutoutandroutergrooveforbackpanel.
Picture3–CabinetFramesidepieces(sideprofile)-
Shownwithoptionalkeyholecutout.
Picture4–CabinetFrametopandbottom–shownwithriser.
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SAFETY–GOGGLES,PAINTERS/DUSTMASK
Picture9–DoorFrame–shownwithroutergrooveforPlexiglasandpre-drilledforscrewsandhinges.
Picture10-12–DoorFrame-assembly