More build pics

Progress has been slow lately due to decorating and the nights drawing in, meaning it's dark when I get home from work.

Having cut the speaker holes in the incorrect positions (spot it in pic), I had to re-cut again.  After the "fun" I had with the round saw piece I used the jigsaw.  They haven't turned out perfect but the plan is to hide the speakers with speaker cloth anyway.  I also decided on the re-cut to swap the speakers (bigger ones) and tweeters (smaller ones) around.

I've decided to use the botched speaker piece to hold fans at the back of the cab. 

An MDF sheet with a hole cut out of it holds the LCD in place. 

Screw in hooks are used for cable management.

Originally I was going to have a flip down hatch rather than a  drawer but it didn't work out so have gone back to the original plans.

Have used filler to fill the counter sunk screw holes, once dried will need to sand.


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MDF Arrives & Cutting Cab Sides

So the MDF finally arrived...the instructions for the courier said "knock loudly" which is not something I requested.  Hopefully Savoy timber request the same for all their customers and not just the ones who make a pain of themselves by constantly phoning to ask where their order is :-)

Seemed well packaged but the edges of the cut were a bit poor and needed sanding :-(

I began by drawing the outline of the cab on the sides and found out the measurements on the plan don't allow enough for the control panel front plus the drawer, so added a bit extra there.

Having drawn out the outline I used a borrowed jigsaw to begin cutting.  The straight cuts were pretty much a piece of cake but I struggled with the curves, the jigsaw wanted to carry on going...

Goggles and a mask were worn at all times!

Rather than cut one side and use that to "trace" the second I'd secured both side sheets together with clamps to make it one run of cuts.  Whether this then made it more difficult to cut the round edges due to the increased thickness I'm not sure.

Once cut, a palm sander was used to smooth the edges and the sides, wood primer suitable for MDF was then applied.

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Wood Ordered!

I've decided that me attempting to cut wood in a straight line across several components is probably a bad idea. 

I tried approaching several local timber merchants and none were willing to cut 18mm MDF boards to size for me. 

I found a company named Savoy Timber (http://www.savoytimber.com) and they gave me the prices below. 

By the time I pay postage probably it will be quite a bit more expensive than buying sheets and cutting them myself but hopefully less margin for error since there will only be the two side sheets for me to cut.

Part (as labelled on Koenig Plans)	Size (mm)	Price
Kickplate	600 x 750	£5.18
Top	600 x 300	£2.07
Under top	600 x 160	£1.11
Button [sic]	600 x 565	£3.91
Monitor suspension	600 x 250	£1.75
Backpanel	600 x 1575	£12.84
Drawer  Front	600 x 52	£0.36
Front Control Panel	600 x 95	£0.66
Speaker Panel	600 x 160	£1.11
Side	600 x 1662	£12.84
Side	600 x 1662	£12.84
Delivery		£20.00
Total		£74.76

I've placed the order tonight, wonder what the quality is like once it arrives? 

I've also just realised that I left out the keyboard drawer from the original quote (doh!) so just shot off a grovelling email to Savoy to see if it can be added.

Edit 25.09.2014 - Savoy have come back to me and allowed me to add the keyboard drawer for £2.50, haven't come back to me about when it will all be delivered though...

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