We needed 3x3 posts to raise the plywood sufficiently away from the the frame so the LED strips will be nearly flush with the external surface. Cutting 4x4s down to 3x3s is not something you want to do on a portable table saw: the posts are long, and since the blade of most saws only comes up 3”, you can’t see where the blade is when you’re cutting: this makes it very easy to accidentally cut yourself. Luckily, Jeff has a woodshop, and lent a hand. Before:
After:
These posts then needed to be mitered at the ends to make the trapezoid of the lower face. After mitering, a notch has to be cut out of the mitered end so that the flange sits midway in the post (rather than the post sitting on top of it): this allowed us to simultaneously raise the external surface out and bring the internal surface in:
The upper faces are 1 1/8” plywood, resting directly on the flanges. We need 1 1/8” because people might stand up there. We might put some framing to raise it a little higher.
The wood arrived at the Box Shop from Lowe’s on Thursday. It was supposed to arrive earlier, but they forgot to deliver it and wouldn’t answer the phone when I called to confirm. So I went to the store and wouldn’t leave until they printed out the delivery schedule and gave me a copy.
So our task on Saturday was to make five more of these. I sketched up the posts in Solidworks and did the panels later that week. Having precise diagrams helped. The right beam is just a mirror image of the left one: note it only has one notch for bolts because the lower bolt is perpendicular, rather than parallel, to the face.
We’ll be mounting the Alucobond on top of these plywood surfaces. On Thursday I’ll be making detailed measurements for the Alucobond and doing a test cut using thin plywood: when each sheet is $500 you don’t want to make a mistake!
Phil
The upper faces are 1 1/8” plywood, resting directly on the flanges. We need 1 1/8” because people might stand up there. We might put some framing to raise it a little higher.
The wood arrived at the Box Shop from Lowe’s on Thursday. It was supposed to arrive earlier, but they forgot to deliver it and wouldn’t answer the phone when I called to confirm. So I went to the store and wouldn’t leave until they printed out the delivery schedule and gave me a copy.
So our task on Saturday was to make five more of these. I sketched up the posts in Solidworks and did the panels later that week. Having precise diagrams helped. The right beam is just a mirror image of the left one: note it only has one notch for bolts because the lower bolt is perpendicular, rather than parallel, to the face.
We’ll be mounting the Alucobond on top of these plywood surfaces. On Thursday I’ll be making detailed measurements for the Alucobond and doing a test cut using thin plywood: when each sheet is $500 you don’t want to make a mistake!
Phil
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