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Discussion in 'Home Cinema Building DIY' started by IronGiant, Jun 21, 2003.

  1. IronGiant

    IronGiant
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    OK, the build is on. The first stage was to build a jig that would function as the equivelant of Taz's £400,000 cutting machine. So I needed something that would:
    1) cut a straight line
    2) cut it in the right place

    I came up with this. It should cut straight with a circular saw trapped betwen the runners, and if I line that cut exactly on the line I want to cut I should be home and dry.
     

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  2. ReTrO

    ReTrO
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    Looking good mate!
    :smashin:
     
  3. RichardH

    RichardH
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    How dare you cut up a piece of STEN :nono: - that stuff's the best value shelving ever.

    How are you going to make sure you get 90 degree cuts?
     
  4. IronGiant

    IronGiant
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    It was surplus to requirements :)

    90 degrees will come from careful measurement and a set square (I hope)

    Just going to do it now
     
  5. IronGiant

    IronGiant
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    Well the jig was a great idea, but the saw snagged and twisted while running up the MDF and my first cut was 3mm out at one end.
    So I used the square sides of that piece to clamp it 96mm downstream of wherever I wanted my cuts (the right spacing for my saw), all the while using a 300mm set square on everything to keep everything true and just have a guide on the one side.

    Seems to have worked really well. (So I cut up that STEN for nothing Rrichard)

    I messed up the first speaker hole because I hadn't properly figured out the router + hole cutting attachment, but fortunately I did the smaller one first, so was able to wedge in another bit of board to get a new centre point and cut it bigger.

    This is a "balance" fit, (hence no central brace yet), no joints at all, it's held together by gravity, which makes me pretty happy it's all going to go together properly.
     

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  6. ReTrO

    ReTrO
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    Looking good.
     
  7. IronGiant

    IronGiant
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    After previous attempts to put together a project in MDF, measured, drawn by ruler, cut with a circular saw, but freehand, I'm pretty impressed by what I achieved by this method.

    Everything is perfectly straight and square and my worst tolerance is that the two front panels may be 1 mm too short. Given they're front mounted to the rest of the box I don't think any one will notice if I leave that underneath where it won't show ;)

    I blame the timber merchant whose tolerance on the long cuts was off by about 1mm :D

    I could try and sand three sides and the baffle down by 1mm, but it's easier to add a strip of veneer to the bottom of the front panel, should I feel it's necessary.

    Dave
     

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