Curved Grill WH10

[Zack Brock]

Now I know Nimrod's secret. He has a Bosch jig saw. Man I miss mine. One of my ex employees exploded it cutting plate. I replaced it with a porter cable that was on sale for 1/2 price, a $200 saw for $100. It's a good saw, but buy once, cry once. I should have sprung the extra and bought another Bosch.

+1 - Found mine in a local pawn shop in like-new shape for $40. Guess the pawn shop owner didn't have the internet to search what it was actually worth as I talked him down to $30. Mine makes table-saw perfect cuts.

And yes, great work and pictures Nimrod, thanks for sharing!

[jjohnson]

Today I prepared the throat fillers.

I used this hot wire 'Styrofoam cutter' I still have from my younger R/C modeling days…
Here placed for slicing a block of foam into two 1" 'tiles':
...

Nice, might have to try that myself.

[N.Webber]

...
Fit testing the raw grills:



Assembling the handles inner pockets:





Handle pockets and ports ready:



Ports in place:



Preparing a handle pocket as a jig for the Piezo array supports:



...And used like this:

[AntonZ]

Curious to see how these handle pockets are going to work out.
You make it look so simple. Somewhat frustrating I must admit, but keep them pictures coming. Nice work, Nimrod!

[N.Webber]

Curious to see how these handle pockets are going to work out.

...Like this:
Drilling the handle’s cutout end radiuses with a 44mm (1-3/4”) dia. cup drill:



Cutting the straight edges:



The handle pocket will eventually be glued like this:



And this is how it will look from outside:



Of coarse the cutouts outer edges will be rounded, as well as the cab’s corner.
Also, the handle inner corner (between the two cutouts) will be fitted with a rounded filler.

[jjohnson]

Of coarse the cutouts outer edges will be rounded, as well as the cab’s corner. Also, the handle inner corner (between the two cutouts) will be fitted with a rounded filler.

Can you tell us the distance you're using from the corner to the edge of the handle? Also, what size of filler have you found to be comfortable? I'm just asking since my last handle was not as comortable as I wanted.

[N.Webber]

Can you tell us the distance...

Here you go...

[jjohnson]

Can you tell us the distance...

Here you go...

Nice!!! Wish I could get my drawings to look that good.

[thomas]

Brilliant build!

[Harley]

Here you go...

What programme is that Nimrod?

[N.Webber]

What programme is that Nimrod?

Gooo...d old SketchUp http://sketchup.google.com/intl/en/index.html

[N.Webber]

Some more cab building:

Handle inner filler glued in place:



All horn braces in place:



Handle pocket glued:



Attaching upper back side pieces:



Adding side flanges for the access panel:



Cab main assembly complete:



Close-up of access opening:



And dry fitting the access cover:



Next/hopefully tomorrow: The part I love… routing

[lazyman]

Really nice work!

Are this white foam good for fillers, its not too soft, or acoustic absorbent ?

[N.Webber]

Really nice work!

Are this white foam good for fillers, its not too soft, or acoustic absorbent ?

Thanks..

I think/hope this material is ok, as I have used it also for my DR290s…
It is relatively stiff and closed cell foam, so to my understanding should do the job.

[N.Webber]

Routing done. The corner rounding was straight forward, 5mm radius for the handles cutouts and 10mm radius for the shell/sides corners.
The front lip edges were just hand sanded to create a radius of about 2mm. I've added recesses for the cabs feet on the two optional bases.



For those interested, here is how I did the logo routing (CNC = See & Copy… )

The router is fitted with a 15 deg. conical bit and a template follower. The depth was set to 3mm (over the template's thickness):



The cab's panel is marked for the center of the logo (in this case, the center of the panel):



The template is positioned up to the center marking and clamped:



The "d" is fitted with the first stage removable 'sub-template':



Routing the first stage complete:



Replacing the "d" sub-templates:



Completing the second stage of the "d":



Template removed, edges sanded lightly, done:



Next: minor Bondo touchups, sanding and… paint.