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I liked the look of the original Defender cabinet and found the dimensions
on the internet. I based my measurements from that. I
created a grid in excel 49x97 representing the 49"x97" mdf
sheet I would be using to build. I used that to lay out my rough dimensions
using the Defender as a model. MDF is normally 1" wider and
longer than your standard plywood sheet, It also has a very smooth
finish that should paint very well. I was basically building
this thing from the seat of my pants. I was unsure
how this thing was going to fit together, so I built a scale model using
black meat trays (you know... the kind you get from the grocery
that holds your raw meat). I licked most of the raw meat off (hamburger .. I think) and built
my model. That was a great exercise, all the parts
seemed to fit like I thought they should, so the full size version
should be a snap. Right? |
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My design was simple. It
needed to be fairly skinny because of the limited space in our game room.
I also wanted to keep the measurements simple. I bought 2 sheets of 3/4 MDF
from Home Depot and had them rip them into four 24"x6' pieces and
two 24"x4' pieces. That way the cuts were pretty straight (better
than I could have done with a circular saw) and they fit in my Rodeo
easier. The 6" pieces were used for the sides and all
the other pieces were used the the middle, top, bottom and control
panel. I would rip them to the desired length as I needed them.
Everything was going to be 24" wide. Simple...right... |
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I screwed the two side pieces together, so when I cut them they would
be exactly alike. My workshop was my mothers green house. I had very little room to work
and was working on a dirt floor. I'm surprised that the thing is
straight at all. Straight cuts were with a circular saw and the
curves were finished with my jig saw. All the corners were rounded
to make it easier to install the T-molding later.
I
used 2x4's to hold the sides together. I used 4 to build a base at
the bottom. I then put one on the top, back and front. I also mounted the
marquee
light. The main reason for that was so I could see what I was
doing. My only other source of light was the Craftsman trouble
light you see hanging from the roof support. The picture looks
very bright, because of the camera's flash. |
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Once
the sides were on I was able to start cutting the pieces for the
inside. That went very quick. I used a 2x4 as a straight
edge and my skill saw to cut. At this point it is beginning to
look like something. I'm not sure what, but what ever it was it sure was
big. |
Control Panel
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