Echo Base
command center
Playset II
This is my second endeavor into MDF (medium density fiberboard). Since I was impressed with the first playset I decided to expand it incorporating it into a "Lightbox" design.
After dissecting the base with a Circular Saw. Jagged edges are layed out and cut with the Bandsaw on the front and partially down both sides to where the side boards will be mounted.
After sanding a oil base paint is applied to the edges. Several coats are needed since MDF is very porous especially on the edges and will suck in water base paint like a sponge.
Next the side boards made from 1x real wood are layed out and cut on the Bandsaw.
The Pergola as I call it is then roughed out and the holes for the lights are Hand Routed in using a template. Rabit edges are cut on the Router Table for the Plexiglass covers.
This process using MDF is sooo much easier and gives a much cleaner look than real wood.
Here the top of the Lightbox was roughed out and riser strips for the ignition bar are bradnailed on. Then the Light Ballast is installed.
With the bulb attached to the tube sockets the assembly is centered over the riser and the insides of the sockets are marked.
Then the sockets are attached with small sheet metal screws (bulb removed) and the wiring is attached with plastic romex staples. The aluminum strips I use for ignition bars are also attached to the risers with sheet metal screws.
The sides of the Lightbox are 1/4"Luan. The front and side pieces are marked with the jagged edge making sure the corners line up properly.
Corner supports are cut on the Sliding Compound Miter Saw and the lightbox is assembled using Glue and Bradnails. The assembly is checked to make shure it overlaps the Pergola properly. Only the top with the lighting assembly will be permanently attached to the sides.
To give the Lightbox a molded-in look I filled the corner joints with good ol' Bondo and sanded smooth.
Final sanding, priming, painting is done before the parts are assembled into two halves. A brass tube is cut to length and painted to run through the lower half for the electrical cord.
The Wiring Harness will be a strip of MDF. A Dado is cut on the Router Table to hide the tops of the harness cables. A wavey edge is cut on the Bandsaw before smoothing on the Stationary Beltsander.
Placement of the harness cables is important so the Computer wires come out in the right places
Plexiglass Panels are cut and the corners rounded before sanding them for a frosted look. The electric cord is attached to the Lightbox and a Luan Back is added. The Lightbox overlaps the Pergola. No fasteners added
ENJOY !!