Its better to small than to big, you can sand parts away that do not fit (picture 4). Carefully cut out the shape with a scalpel and try to be as precise as possible. Trace the cardboard shape on the wood veneer. Gently peel off the tape and stick it on a piece of thin cardboard. This will be the biggest piece and you need to cut out a difficult shape.Ĭover the whole top size of the case with paper tape and cut out the shape (picture 1). Let it rest overnight before remove the tensioning Screws and sand with sandpaper 120 where needed (picture 3). Then put in the piece of plywood and apply pressure with tensioning Screws. Degrease everything and put the glue on the case. Again cut out the piece with the jigsaw and look if everything fits. Now measurer the piece in the front and draw it on the plywood. Sand the plywood if it comes above the case. Let it rest for a night and remove the clamps. If everything fits you can glue in the piece and put pressure on it with tensioning screws (picture 2). Now draw the insides of the hole on the plywood and saw it out. Drill some holes and use the screws to secure everything in place, countersink the holes to ensure the head of the screw is level with the case (picture 1). Luckily I had some plywood with the right thickness lying around.ĭraw out a shape of the hole that is bigger and cut it out with a jigsaw. In my case i had a hole from the old arm and a piece on the front to fill up. It dind't had to be perfect because the PU-glue will fill up the small gaps. To glue the veneer on the top sides I needed to level some shapes in the case first. Again sand them to the right size and finish with 320 (picture 9-10). Now cut out the top and front sides (picture 4-5) and glue them (picture 7-8). Sand the pieces that are to large untill they fit nicely. Glue the sides first and keep it under pressure with your hands, the glue hardens in a few min. Now you have the shapes, you can draw it on the veneer and cut it out with a scalpel (picture 4).īecauce the parts are small i will glue them with two component glue so i can work faster. Carefully peel of the tape and stick it on the thin cardboard and cut it out with the scalpel (picture 3). Then take a scalpel and cut out the shape. Take a small piece of paper tape and stick it on the sides of the small parts. The smaller parts will be glued in a darker color wood veneer.īegin sanding the surface with sandpaper 120 and degrease (picture 1-2). If you sand the corners you will see that they fit nicely together (picture 6). Take the 120 sanding paper and sand off the parts that stick out the case (picture 4).ĭo the same with the front and back (picture 5). Let it rest overnight and take off the screws. The PU-glue will fill up the spaces that don't come together nicely like the corners. Put the planks in place and apply pressure with the tensioning screws. The glue will go through some veneers and the plastic ensures that you get everything won't stick together.ĭistribute the PU glue evenly over the surface and spray a little water over it. Now make a wooden plank for the outsides of the case and wrap them in the plastic and sucure it with the tape. Sand the surface of the edges that has to be glued with sandpaper 120 and degrease them. It is important that the pressure is equal everywhere, so saw off some wooden planks for the inside of the case. Take the box cutter and cut out the pieces (picture 2). Measure the front, back and the 2 sides and draw the shapes a little bigger on the wood veneer (picture 1). Any veneer will do and if you want it in one piece then make sure that the piece is big enough. Now it's time to glue the wood veneer on the case. Take off the screws and your ready for the next step (picture 3). Leave it over night to make sure that the glue is hardend. Do the whole length or the profile will have different hights. It will not stay in place so take some wooden planks and press it together with the tensioning screws (picture 2). When it has the right round shape, put the glue in the insides of the U-profile and put it over the brim. Measure the lengths you need and cut off the pieces and try to bent it in shape over the brim with no glue ( picture 1). Take the brass U-profile and glow it with the gas burner to soften it. The brim alround the disc had the right size for the U-profile to fit over. I wanted to use brass parts in the design for a more appealing looks.
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