Weekend 3 Plan

Saturday:

• cut plexi
  
• attempt to clean up cuts already made
  
• finish cut sides

this may require me to start putting legs on to work out which walls will need to be trimmed down.

Sunday:
do what I failed to do on Saturday...

another post

jeez, there have been long gaps in my productivity on this!

Anyway, scored two more bamboo mats for a new surround for the extended cabinets. I had to check four places before finding anything (as well as a few web searches) so as you can guess I was getting a bit concerned.

The umbrella skin has been patterned. Now I just need to clear a huge space on my floor and start cutting. That will likely happen next week as we have a party to prepare for this weekend.

I'll take photos for the next steps.

Progress plus!

Forgot to point out that Tiny and Irk were also working on distressing some more skulls Sunday. These will be used as display stands for the fezzes... and whatever else we need.

They already look fantastic and that is only with the first wash.

Progress!

Made some headway yesterday with Smokin' Joe's help. We got most of the tops and bottoms of the displays cut and sanded with only a few mishaps.

I've learned two things this weekend.

• The circular saw doesn't cut as clean as the router/template set up.
  
• The router/template set up produces massive amounts of dust... massive.

The sides are roughed out but still need their final cuts. Half of them need to be a 1/4" shorter than the others to accommodate the 1/2" MDF vs the 1/4" Plexi. This is good because I cut a few of them a bit close.

Up next: cut the Plexi and work on the hinge situation.

momentum?

Saturday Morning. While I wait for Irk and Ikabod to run their respective errands and arrive I will try to get the display case template done.

I will be able to cut 8 decks and a dozen sides which will leave me one deck short after adding the three cut from plexi. I may have to cannibalize one of the old display cases.

Hopefully the hinge concept will work on the first try...

Lull

Gotta love the work week... One more day of paid labor and I can get back to my not-paid labor!

Didn't get as much done as I wanted to last week so now I have to play catch up to keep on schedule. My plan is to be done with the booth by April 1st so I can spend the next month focused on product.

However I do have design responsibilities that will get in the way... and there are always those last minute design alterations.

I plan to cut a template before Saturday, so this weekend is all about productivity!

parts list

Display ring based on 8ft ring made of 12 sections. 6 sections to produce 180º. The Uberfez used 2 sections to cover a 90º opening based on a smaller diameter to accommodate the wall taper.

Cases
1/2" MDF 4x8 sheet $17.89 enough to make 6 sets of bottoms and walls with a bit left over.
0.22" Plexi 24"x48" sheet $39.99 enough to squeeze out 3 display tops. The Uberfez used .09" plexi which wasn't very sturdy.

Legs
28" taper legs $5.99 per. We used 3 legs per cabinet before but if we bolted each section together we could shave off a few legs.
Threaded leg plate $1.49 each

Approx. $40 per cabinet. If we only make 3 of them with Plexi tops then we would save the $13.33 per Plexi top.

48" piano hinge $9.19 could be used to make the walls fold flat for storage.