This document is under construction.
Last modified by Tadd - Mar 8 2018

Creating a parts kit from raw lumber

Note: This section is not complete or tested. Please contact NC4FG directly (good in the callbook) to get latest instructions.

Tools Needed -- cut the wooden parts

Table Saw
Scroll saw or Band Saw or Coping Saw
23 gauge pin nailer with 3/4″ and 1/2″ pin nails
Needle nose pliers to pull out pins
Putty knife for prying apart blocks
Fine-tip pencil for marking
Tape measure

Jigs

C	Obsolete
D	Front-Corner-Jig	1-1/2″ x 3″	Used in Wood Cutting to set the location of the front slot.
E	Front-Slot-Jig	2″ x 1-3/4″	Used in Assembly and Wood Cutting. In Assembly the 2″ width of this jig is used to position the Scope-Panel. During Wood Cutting, the builder will draw the shape of the front slot using this jig
F	Back-Corner-Jig	1-1/2″ x 2″	Used in Wood Cutting to set the location of the back slot.
G	Back-Slot-Jig	1-1/2″ x 1″	Used in Wood Cutting. The builder will draw the shape of the back slot using this jig
H	Top-Panel-Jig	10-3/4″ x 7-3/4″ with a 1-5/16″ square removed from each corner.	Used in Assembly and Wood Cutting. During Assembly, this is used to position the inner footpads on the bottom of the box and also to transcribe the center-lines during positioning of the Top-Panel
I	Top-Panel-sizer-Jig	2″ x 13″
J	Top-Panel-sizer-Jig	2″ x 13″
K	Circuit-board-holes-Jig	5-1/4″ x 2-1/2″
L	O-scope-panel-holes-Jig	5-1/4″ x 4″
N	Edge-scrap-Jig	5″ x 3/4″
O	Edge-scrap-Jig	5″ x 3/4″

all_the_jigs_2018feb16_0002_004x800

Materials List -- Cut the wooden parts

4′ x 8′ sheet of 1/2″ sanded plywood primed on one side. I use Lowes Top Choice Blondewood 1/2-in Whitewood Plywood ($37). HERE is a link. I get Lowes to cut it in half for easier 4′ x 4′ transport dimensions.
4′ x ‘4 (maybe less) of 3/16″ (5 mm) sanded plywood primed on one side ($15). I buy a full sheet and it lasts many boxes. HERE is a link.

Cut Diagrams

4′ x 8′ sheet of 1/2″ plywood
mod-box-cut-sheet-4x8small

Each 15″ x 48″ piece gets cut again. -- Note: picture shows major cuts only
mod-box-cut-sheet-4x15in

Wood-Cut Step 1: Making the wood cuts

1		Starting with a 4′ x 8′ of 1/2″ Birch plywood, cut the long dimension into 15″ sections. The cut has to leave at least 14-3/4′ as that dimension will be shaved later. Each of the 6 pieces will be 48″ x 15″ and each of these should make one box.
2		From one of these pieces, make the following cuts:
	a	Long-ways, make a cut at 11-3/4″ to make a piece 11-3/4″ x ~15″ will be Box-Roof
	b	Long-ways, make a cut at 11-3/4″ to make another piece 11-3/4″ x ~15″ will be Box-Bottom
	c	Long-ways, make a cut at 5-1/4″ to make a piece 5-1/4″ x ~15″ will be Box-Left-Side
	d	Long-ways, make a cut at 5-1/4″ to make another piece 5-1/4″ x ~15″ will be Box-Right-Side
	e	Turn the remaining piece 90 degrees and make a 5-1/4″ cut to make a piece 5-1/4″ x 13-1/2″ will be Center-Support
3		Make the following cuts to create the designated parts common to both types of boxes:
	a	Cut the &15″ length from step a above to 14-3/4″ to make the Box-Roof
	b	Cut the 15″ length from step b above to 14-3/4″ to make the Box-Bottom
	c	Cut the 15″ length from step c above to 11-3/4″ to make a Box-Left-Side
	d	Cut the 15″ length from step d above to 11-3/4″ to make a Box-Right-Side
	e	Cut the 13-1/2″ length from step e above to 6-3/4″ to make the Center-Support of 6-3/4″ x 5-1/4″. Also cut a 3/4″ piece from what is left over to create the Front-Right-Panel-Brace of 5-1/4″ x 3/4″
4		Cut the remaining parts to make the following:
	a	9″ x 8-1/2″ O-Scope-Pan
	b	5-1/4″ x 4″ Scope-Panel Not Anymore????
	c	5-1/4″ x 3/4″ O-Scope-Panel-Brace
5		If working on a radio box, cut the remaining parts to make the following:
	a	Two 5-1/4″ x 3″ parts to make the radio-block
6		From what is left over, cut the two 4-3/4″ x 3″ floor and ceiling supports
7		From a 1/4″ sheet of plywood, cut the following parts:
	a	10-3/4″ x 7-3/4″ top panel
	b	5-1/4″ x 2-1/2″ circuit board panel
	c	Four 1-1/4″ x 1-1/4″ footpads

Wood-Cut Step 2: Drawing the slots

1		Place the Front Corner Jig on the right front corner of the box top. Make sure it aligns to the front and side edges. Place the Front Slot Jig just to the left of the corner jig and make sure it is aligned to the front edge. Press down on the slot jig so it doesn’t move, remove the corner jig, and draw a line around the 3 edges of the slot jig.
2		Perform the same procedure to the right front of the box bottom.
3		Perform the same process with the back left corner of both box top and bottom using the two jigs designated for the back corner and slot.

Wood-Cut Step 3: Cut the slots

Cut the front and back slots from top and bottom. I use a scroll saw, but a band saw or hand-held coping saw would work too.

Wood-Cut Step 4: Create the top-panel and footpads.

1		Put the Top Panel Jig on top of the top panel.
2		Trace the jig cutouts onto the top panel.
3		Cut out the top panel cutouts by cutting inside the pencil marks.
4		Place the top panel on top of the Top Panel Jig and transfer the front and side center edge marks.
5		Trim the 4 footpad-sized pieces cut out in step 3 above so each is 1-1/4″ square or less.