Actual thickness is 0.196". That's slightly over 0.1875" (3/16"), but they call it 1/4", LOL!
I cut the parts out with the Trio, a cutting bit & a straight-edge.
1 Back: 10"h x 12.2"w
2 Sides: 10"d x 12.4"h
2 Top/bottom: 10"d x 10.2"w
Notice the back height is equal to the depth of the other parts - all are 10". This is one less adjustment or measurement to make when ripping the parts.
I used the 1/4" straight bit to make the groove for the back which is slightly wider than the plywood. But I'll fix that later.**
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| I cut a 1/4" groove in the top, sides & bottom. I cut the groove half the thickness of the plywood, about 3/32" deep, & about a 1/4" from the edge. |
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Using the chamfer bit I beveled the edges of the same 4 parts.
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| I sanded down a 1/4" x 3/8" piece of basswood to use as a trim on the front of the roombox. That is sanded 1/4" down to 0.196 to match plywood thickness. I rabbeted it 1/10" deep & about 1/16" on each side creating a tongue. Then on the front edge of each of the 4 parts I cut a centered 1/16" groove to accept the basswood trim. Sorry I used a mini table saw for that. If Dremel made 1/16" straight bit for the Trio I would have used it. I guess you could just glue basswood w/o the tongue & groove. And you could use a standard piece of stripwood for the trim. |
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| Dry fitting sides, top & bottom around back - which is fitted into groove. |
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| Back fitted snugly. |
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| Dry fitted front. (showing masking tape holding box together) |
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| Make sure the grooved side of each piece is aligned to the straight-edge. Then with masking tape tightly apply the tape while pulling the parts together - keeping them aligned to straight-edge. |
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| Carefully flip over the assembly. Notice that the grooved edges are all aligned at the bottom. |
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| Apply glue to all the bevels & grooves. |
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| Close up of glued areas. |
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| Fold the sides, top & bottom around the back & tightly tape the top & side to complete the box. |
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| Wipe off any glue squeeze-out. |
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| All seams cleaned. |
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| Turn the box with the back facing up & **apply weight to the back to push it down to make it tight & flush on the inside. Remove the weight only if you're using clamps ** I clamped all the sides & put some extra tape here & there. |
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| After the box has dried - glue & tape down the front trim. |
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| Box almost finished - just need to check for any gaps, if so I'll need to do some filling & a bit of light sanding.
Not too shabby for lauan!
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A sliding plexiglas front could be fitted at this point, but I think I'll do a storefront instead. It will fit snugly & will be removable.
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