Initial Prop Construction

Basic Box Units Construction

Using what was learned from the research, sketch ideation and prototyping and using tools I had purchased from what was learned on the course and that I had purchased from earlier project attempts.

The three primary tools were my:

• Evolution Mitre Saw
• Draper Disc Belt Sander

and the amazing

• Finn Multi Master Multi Tool.

These I used to cut out the basic panels to start with the fit them together factoring  in a cutting gap for the blades to be trimmed later to size with the disc belt sander.

I experimented with brackets to fit the boxes together out of MDF but these was too messy.

Filler was used to fill gaps.

The disc belt sander was used to trim parts precisely and align and level parts out.

The multi-tool is super versatile doing with nothing else can both the sand down, trim and cut. Thus was used along side my power file depending on the nature or the work needed doing.

the Multimater was also exellent at cutting slot groves for the panels.

It also enables trimming in awkward places as well as far safer cutting when the use of the mitre saw was too risky.

PVC tubing was used to reiforce the box stucture on the inside.

3D printed panels were also used to help position hinges, laid undernesth and superglued into place.

To get the holes correct for the handles I drilled one hole then loosely screwed one end of the handle in p;lace and used that to ger a precise position for the second hole.

Control Panels Cutting Guides

The control panels were started by using what I learned from the prototyping stage, the create in Illustrator cutting guide sheets which were stuck on the panels and used to guid drilling and slit cutting with the Finn Multi Master.

Once the holes were cut  out of the MDF sheets I created top panels in Solidworks which were then 3D printed, then smoothed with filler and sanded  to make mock metal panels to go under buttons and hide the less neat holes and slots.