Update - Finally some progress!!
Finally got back to work on this thing, all my parts are in, had a heck of a time finding the tools to machine these large acrylic rods but it's done!
I'll be using four of these vertically as the main support for the case, with a sheet of 1/4" acrylic glued inside a groove in the side of each one. Needless to say, the grooves had to be perfect. Here's a shot of one of them with a single groove.
These grooves couldn't go all the way through the rod, as the tops are going to be visible and polished, so I had to set up a stop block before cutting any of them so they would all be exactly the same length.
The end of one groove:
One groove was pretty easy really, but the other groove on each column had to be exactly 90 degrees to the other, since they are corners. How to do that? Found a simple solution:
Set two grooves side by side, connect them with a narrow piece of scrap:
And bingo. Leave them connected like that and run them over the router, the groove that's cut on the bottom is a perfect 90 to the one on the side. :D
All done:
Now there also have to be short grooves *across* the columns for the top and bottom pieces. And they have to be perfectly 45 degrees to the two grooves I already cut. Same method:
Hook two *equally sized* pieces of scrap into the two grooves and set the rod on these pieces. Automatically sets the angle perfectly to 45 to the router bit.
This is a rather poor shot of the front piece with the layout for the holes on it. Ran out of time to actually cut them tonight.
I did, however, get the columns and all four sides put together loosely just to see what this thing will look like. I like it.
And I just had to lay some of my UV tubes in there to see if they were going to shine brightly enough through the tinted acrylic. The picture is awful, I know, but it looks like the lights will work. I have more coming anyway. :D
That all for this week, will start cutting the top and bottom next week, finish designing the inner support structure and hopefully get some components in there!
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Suzuki gs1000s