Day 324 - Multiple Updates

Post date: Feb 15, 2014 3:54:28 PM

It has been a while since the last post. However, I have been working on the TARDIS tissue box. Since the last post:

• • The "flower boxes" were mounted

  • The panels have been paired & glued together

  • Planning for the TARDIS light effect & sound continues.

Placing the "Flower Boxes"

I'm finding that somewhere along the way, my measurements aren't matching the plans. On the first one I made, I printed the plan on an 8.5x11 piece of paper and meticulously measured and scaled each measurement up to the size I wanted. It was tedious, so this time I thought I would just print the plans at scale. Somewhere something happened. I think I wasn't as meticulous. So the measures now are less prescriptive and are more for general guidance. I'm using the panels for reference and the plan secondary. I think I'll still achieve the end effect and any scale or look issues will only be detected by me. 

As for placing the flower boxes, this was initially by "look" and measurements from the actual panel. I centered the box and placed it about one door frame width above the door. Cutting carefully into the corner pieces, I was able to pry them up. There was occasionally some splitting to the surrounding area, but wood glue fixed that. I also (after several nicks) used a thin piece wood to protect the base of the panel as I cut. 

Gluing the Sides Together

During the building of my first tissue box, I created a wooden L frame to help assist me with aligning the sides.

The "sand bags" came in handy again as you can see.

I then picked to panels and made sure that the edges fit well together. I then placed two panels in the frame, checked the position and glued the edges together. I added a short square beam to the seam as well to provide true strength in case the seam didn't have strong surface alignment. 

Since the corner pieces are higher than the bulk of the panel, you won't get a true 45 degrees. So, I used some scrap pieces to fill in panel in order to "true up" the angle. Also note that the "flower boxes" are overhanging the top of the frame. 

Now that the glue has dried, I see some gaps in the seam. No worries, I'll fill this in with some wood putty. I also discovered that my plan to pre-angle the plywood base and then sand the balsa by hand didn't work out perfectly either. Hopefully, you have better tools available like a belt sander or disk sander machine that will allow you to get exactly 45 degrees. You may even be able to use a router, but I'd be very worried. Big Tip: Practice on some mock up pieces before you try anything on your panels. 

I've fit up the 4 sides, and see that I'm going to have to do some sanding to get the two halves to match up nicely. 

TARDIS Light

I've been experimenting and thinking about this a lot. I went to the hardware store and purchased several short pieces of clear plastic hosing of varying diameters and brought them home. The biggest of them seems to work the best. Problem is that when they manufactured it, they coiled it and so the hose has a curl and is more oval than circular. I purchased a dowel rod and have been experimenting with slightly heating the pipe in order to stress relieve it as I make it more circular and straight. I scorched the first piece a bit, but it did straighten and remained circular. It also appears to have hardened the plastic slightly. 

Then I was able to take the hose to the craft store and hardware store to find the right top. I looked at wood plugs and wooden wheels. I found some wooden wheels that I think will work. The plugs were a good option too, but the larger ones are also longer which means you'll have to cut them down. The plan is to mount the tube, use toothpicks for the side pieces and mount the wheel on top. Will keep you posted. 

I'm also concerned that the light from the toy TARDIS won't fit in the tube. I'll see if I can extract the LED, but if not, I may have to cut it off and wire another one on. Will also keep you posted.

I also purchased paints. I found the base blue in stock (will post details later) but couldn't find the secondary blue I use for highlighting. I think I found a reasonable substitute and will practice on scrap pieces.