Pinewood Derby Display Case - FINAL[1] - Cub...

DesignbyNeilFern-Pack187

PinewoodDerbyDisplayCase

OptionalDoor

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SAFETY–GOGGLES,PAINTERS/DUSTMASK

Front

FinishedInteriorDimensions

217/8”(H)

X9”(W)X

3”(D)

4”Heightbetweenshelves

ExteriorDimensions23½”(H)X10½”(W)X3½”(D)

Back OPTIONALDoor

Finishedinterior203/8”D

X7½”W

Finishedexterior23½”X101/2”

Routergroove¼”offbackedge-slightly

deeperthanthedado/routershelfcutstoallowforbackpanel

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MaterialsListMediumandfinesandpaper/sponge.Two12”woodclamps,woodglue.

CabinetFrame-LumberNominalSize1”X4”X72”ActualSize¾”X3½”X72”Shelf-LumberNominalSize½”X4”X48”ActualSize7/16”X3½”X48”

BackPanelNominal/ActualSize¼”X12”X30”(ConsiderMenards®SKU:4794561)

Notes:Thinkaboutthetypeofwoodyouwouldliketouse.Mahogany,oak,cherryandpinecouldbesomepopularchoices.Eachtypeofwoodhasitsowncharacteristics.Startthinkingabouthowyouwantyourfinishedproducttolookbeforeyoustartpurchasinglumber.Chooseboardsthatarenotwarped.Longerboardstendtohavemorewarptothem,inspectyourlumberwellbeforeyougototheregister.ThebackpanelcanbemadefromaplywoodveneerhoweverIfounditdifficulttofindapiecethatwas“clean”andendedupusingacabinetendpanel.Dependingonyourchoicesafinishedproductcanrangefrom$15-$35.

OptionalDoorDoorFrame-LumberNominal1”X2”X72”Actual¾”X1½”X72”

Plexiglas/Acrylic1/8”X12”X24”Note:Actualthicknesswillbearound0.118”.Smallsheetscanbehardtofind,andyoumayneedtobuyalargersheet.Hinges(non-mortice)&ScrewsManyhingechoicesareavailablebutconsiderRocklerpart#028670whichareverylowprofileandhelppreventdoorbinding.Four½”woodscrews&clasporhooktosecuredoorshut.

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EquipmentNeeded

NotnecessarybuthelpfulTablesawwithdadoblades(upto½”stackedbladesforwidecuts)(Youcanuseatable,miter,circularorhandsawfortheroughcuts.)

NecessaryRoutertablewith1/4”bitsforbackpanelgroove.NOTE:1/2”and3/8”routerbitsarerequiredifyouarenotusingtablesawdadoblades.OptionalDoorrequires1/8”routerbitandtablesawlaminatebladeorlaminaterazor(cuttingPlexiglas).

OrderofOperation/RoughCutsUseatable,circular,compoundorhandsaw.

Donotassumethefactoryendsarestraight–makeafresh/straight-cleancut.CabinetFrameUsingNominal1”X2”X72”–cuttwo23½”piecesandcuttwo10”pieces.

ShelvesUsingNominalSize½”X4”X48”-RIPboardreducingActualdepthfrom3½”to3”.Cutfour9½”pieces.Atablesawwillmakethiseasier.

BackPanelUsingNominal/ActualSize¼”X12”X30”cutdownto22½”X97/8”.

OptionalDoorFrameUsingNominal1”X2”X72”–cuttwopieces23½”(stile)andtwo10½”pieces(rail).Using1/8”X12”X24”Plexiglas/Acrylic-cuttoreduceto81/16”X211/16”.Note:besuretouseabladeorknifeapprovedforPlexiglas.

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DesignCutsCabinetFrameMakethefollowingcutsonboth23½”CabinetFrameSidePiecesusingatablesawwithadadobladeorrouter.

Notes• Thetopandbottomcutsaredifferentthantheothersinbothsizeand

depththantheothercuts.• Thepieceissymmetrical.Onceyouhaveyourtablesawdadobladeor

routertablesetupfortherightwidthanddepthyoucansimplyswingtheboardaroundtomakethesamecutontheopposingendANDotherboard.

• Makethesamecutsonbothpiecesbeforechangingbits/bladesordepth.• Remembermeasuretwiceandcutonce,beprecise.• Blowout(tearingofwoodfibers)canfrequentlyoccurwhencuttingacross

thegrainofthewood.Puttingapieceoftapeoverthebackofthecut(endofcut)canhelpreducetheseverityoftheblowout.Sandcutsclean.

Lookingattheleftcolumn,topcutbelow(seehighlight)“Dado½(D)X3/8(W)”meansusinga3/8dadostackor3/8routerbitwide(W)setat½”depth(D).

3/8”HDado½”(D)X3/8”(W)

4”1/4”(D)X½”(W)dado4”1/4”(D)X½”(W)dado4”1/4”(D)X½”(W)dado

4”1/4”(D)X½”(W)dado4”Dado½”(D)X3/8”(W)

3/8”H

3/8

3/4

43/4

51/4

91/4

93/4133/4

141/4

181/4183/4

223/4231/8

Markthenarrowedgeofyourboardswiththese12measurements.

Thesewillbeyourshallowcuts.

(SeePicture1)

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CabinetFramecont.Makethefollowingcutsforthetop&bottomofCabinetFrame-usinga½”tablesawdadobladeor½”routerbit.Takethetwo10”piecesandremove½”WX3/8”Dwideoffeachendofboard.Sandcutsclean.NOTE:Blowoutcanfrequentlyoccurwhencuttingacrossthegrainofthewood.Puttingapieceoftapeoverthebackofthecut(ENDOFCUT)canhelpreducetheseverityoftheblowout.

Router-GrooveforBackPanelAftercompletingallofthecutsaboveonallfourpiecesusearouter(table)andrunagroovedownonesideofeachboardwith¼”bitat½”depth,centeredat5/16”offbackedge(leave¼”offbackedge).NOTEitmightbeeasiertomakeseveralshallowpassesworkinguptoa½”depth.IMPORTANT:Donotrouterstartingorending3/8”ontheCabinetFramesidepieces-stopinthecutout.Optional:ifyouwouldliketohangyourdisplaycaseyoucanuseakeyholecutterrouterbitonthebackofbothpieces,setdepthofcut¼”.BesuretocutattheexactsamelocationonbothCabinetFramesidepieces.

Top&BottomFramepiecesCutgrooveonsidew/ocutouts

Stop

SidepiecesGrooveonsidewithcuts(SeePicture1and2)

SeePicture2

SeePicture3

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CabinetFramecont.ONLYifyouarebuildingtheOptionalDoor-thedoorframewillobscurepartofthePWDcaronthelowestshelf.Tocorrecthisyoucanaddariserusinga7”remnantofthe1”X2”lumberfromthedoorframe.

CabinetFrameAssembly

Viewfromside

ScrewtherisertotheCabinetFramebottom

piecewithtwo1¼”woodscrews.Centerlefttorightandfronttobackofgroove.

Center

Groove________Viewfrom

top

AddwoodgluetoallFOURFRAMEcorners-clampuntilgluesets.

SlideBackPanel

intogroove

SeePicture4

SeePicture5-8

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OPTIONAL:CabinetDoor-Cuts

Usepiecesmentionedonpage4-OrderofOperation/RoughCuts-two23½”(stile)andtwo10½”pieces(rail).Topreventblowouttapeendofcut.Remove1½”X1½”X3/8”Doffeachendonall4pieces(8cutsintotal)tocreatelapjoint.Todothisyoumayneedtomakeseveralpassesonyourtablesawwithdadobladeorroutertable.Tokeepyourcutsuniform,passeachside-ofeachpiecethruyoursaworrouterbeforemovingthefenceforthenextcut.

Sandcleanwhenyouarefinishedwithall8endcuts.Usingaroutercreateagroovedowncenterofall4pieceswith1/8”bit-¼”D.Donotroutergrooveinstartingorending1”ofboard(youwillmakeapartialcutintothelapjoint).Thiscreatesthegapfortheplexiglass.

Stop SeePicture9

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OPTIONAL:CabinetDoor-Assembly

Notegroovesonboards.Addgluetostilelapjoint.

Screwlapjointofrailandstiletogether(slightlycountersink).

SlidePlexiglasintogroove.

Addgluetostilelapjoint,secureadditionalrailwithscrew.

Rail

Stile

Glue

Recessfacedown--------------------------

Recessfaceup

Screw

Plexiglas

Screw Glue

Screw

SeePicture10-12

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Glue

OPTIONAL:CabinetDoor–AssemblyCont.

Addgluetobothendsofstile,slidestileunderrailsandintoPlexiglas.Screwtogetherandclampuntilgluesets.

Installhinges.Considerpredrillinghingeholes,thesescrewstendtobeverysmallandbreakeasily.Iftheunitisnotwallhung,considerraisingthedoora1/16”offthebottomofthecabinetsothatitcanbeeasilyopenedwhilesittingonaflatsurface.

PlexiglasPlexiglas

Completedbackofdoor

Hingeholes

SeePicture10-12

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Stainorpainttomatchyourtaste.IfyouwouldliketoleaveitnaturalIdosuggestavarnishorpolytopreventlongtermwarping.Installknob–considerusingaPinewoodDerbywheelandaxel.InstallClasptoholddoorshut.

LoadwithyourPinewoodDerbycarsandenjoyyourPinewoodDerbydisplaycase!

Iwouldlovetoseeyourcompleteddisplay–[email protected]

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Picture1–CabinetFramesidepieces-Shownwithframecutouts,shelfcutoutsand

routergrooveforbackpanel.

Picture2-CabinetFrametopandbottom–shownwithframecutoutandroutergrooveforbackpanel.

Picture3–CabinetFramesidepieces(sideprofile)-

Shownwithoptionalkeyholecutout.

Picture4–CabinetFrametopandbottom–shownwithriser.

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Picture5thru8–CabinetFrameassembly.

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Picture9–DoorFrame–shownwithroutergrooveforPlexiglasandpre-drilledforscrewsandhinges.

Picture10-12–DoorFrame-assembly

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Pinewood Derby Display Case - FINAL[1] - Cub...

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