Wednesday, 9 May 2012

DJ Booth.

I had an enquiry about a month ago for a curved DJ Booth, so I'm in the process of making it now and thought I would document the build.  Here is the overall design..

As you can see the corners are curved, and the front and returns are made from solid oak with a chamfer detail at all the intersections.

First job was to make the former for the curved corners, and that starts with a piece of 9 mm mdf and a hole.

I then need to use my radius jig for the router, its a piece of timber with a couple of spare guide bars from an old router, housed in for my router to attach too.

Just a matter of putting a screw in the marked centre-line.

And placing that on my pattern board.

Attach the router to the radius jig and line up to the required radius.

Then cut.

I then ripped a load of what will become my ribs for the former, they are made from scraps which is why they are from different materials, I have numbered and and used the cabinet makers triangle to ensure they are in order.

Then its just a matter of rough cutting the ribs, screwing the template that I cut earlier to the rough rib and routing.

I'm using a pattern cutting bit in my router for this.

Which gets me to here, the board under the ribs will become the base to my former.

Its then a case of gluing and screwing the ribs to the base board.

Then I need to transfer the rib spacings to a piece of 8 mm bendy ply, and mark the centre.

Run glue over the ribs, pin the centre line and work my way to the edge

One former, about 5hrs work.

I then got on with machining the oak for the front and returns.

Thats as far as I've got today.  Thanks for looking.

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