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[Build Log] - Desk 9 - Page 4

post #31 of 146
Thread Starter 
Update

Today I received all of the pieces required to complete full scale testing for attaching the 3/4" acrylic top to the desk. The parts list includes 1" x 1" x 24" Aluminum, Steel Set Screws, Steel Shouldered Screws, Steel Threaded Wood Inserts, and 3M VHB tape. I also used sample pieces of Acrylic and Plywood to receive the custom fitting. The initial concept sketches below illustrate the assembly, with photos and description to follow. Video will be added tomorrow evening showing a couple steps of the process.

Enjoy!


Photos

(Click to show)

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Initial Concept Sketch

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The first step is cutting the aluminum stock. For this, I used a metal cutting band saw.

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The final desired thickness of the aluminum fitting is 3/8". I cut them at 1/2" thick because, as you can see, they are a bit rough right off the band saw, and will require a run through the mill.

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The mill did a wonderful job at providing two very smooth and parallel surfaces.

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I score the bottom of the aluminum fitting to locate center for drilling the hole to receive the shouldered screw.

90f2fd46_WP_20140201_021.jpeg

The hole is drilled with a two step process, one standard bit followed by one flat bit. Here it sits next to the shouldered screw with head milled off. But will it fit?

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It does!

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I repeat the process for drilling the hole to receive the set screw.

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I also tap it. There's always a risk to cut the threads crooked, so I proceed in a cautious manner.

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The threads are cut but will it all fit together?

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It does!

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I then polished the mating surface of the aluminum fitting in preparing to adhere it to the acrylic. I think it looks quite polished, especially next to my grimy hands.

2c09661b_WP_20140201_042.jpeg

Next the acrylic is taped off as a guide for adhering the aluminum fitting to it.

b2d4b117_WP_20140201_043.jpeg

3M VHB tape... this stuff is used to hold glass onto steel frames in skyscrapers.

b21c35e5_WP_20140201_050.jpeg

The threaded wood insert is installed in the scrap piece of plywood, with shouldered screw in place.

6b94f25b_WP_20140201_045.jpeg

Here the aluminum fitting has been taped to the acrylic, slipped onto the shouldered screw, with set screw tightened. Applying force in any direction except rotational in X/Y results in zero movement. Rotational X/Y results in a fair amount of movement because the VHB is stretchy, but when 9 other pieces are attached to the real thing, the acrylic top would not rotate. The test is a huge success and I am very pleased.

e21d1169_WP_20140201_046.jpeg

There are some small air bubbles in the tape, but has a far better appearance than what I could hope to achieve with glue, is much easier to work with, has an instant bond, and is something I am certainly very pleased with.

Edited by hingfdiuh - 2/2/14 at 8:50am
post #32 of 146
Thread Starter 
Below are some short clips of the cutting and milling process. This week I will finish polishing the fittings, order the acrylic top, and install it all next weekend.

Videos

Cutting - http://youtu.be/eXgxdrFt74Y

Milling - http://youtu.be/wMOJa0ols_k
post #33 of 146
Hey man,
Figured I would take a look at your project since you had some questions on mine! Looks awesome dude! Hopefully everything comes together well. The torsion thing is an issue I saw you were having. My suggestion: Angle Iron. Might give you a good stiff backbone and keep it from getting that weird movement. Just add to the rigidity hopefully.
My 2 cents smile.gif
Great looking design though! Looking forward to the finished product.
post #34 of 146
Thread Starter 
I committed to placing an order for the acrylic desk top. The total cost after labor and taxes is $701.39.
post #35 of 146
Thread Starter 
Update

Today I finished cutting, milling, drilling, tapping, and polishing the pieces for the custom aluminum fitting assembly. I also installed the custom aluminum fitting assembly onto the acrylic top, and verified that the previous wobbling has been significantly eliminated thanks in large part to the weight of the acrylic top (70 lbs.) and the locking action of the aluminum fitting assembly. I had to resist the urge to peel the protective film off of the acrylic top. Now that this unanticipated problem has been resolved, and the top has been secured, I will proceed to fill, sand, and otherwise smooth out the desk to prepare it for the rubber paint.


Photos

(Click to show)

acb805f0_WP_20140216_002.jpeg

I had some help making sure the holes were drilled straight into the desk.

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The acrylic top with protective film.

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Threaded insert.

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Shouldered screw (unmodified).

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Shouldered screw (modified).

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Corners get two set screws to continue the visual lines of the desk.

d95d0c45_WP_20140216_016.jpeg

All of the custom aluminum fittings are on.

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3M VHB tape is added to each custom aluminum fitting.

983df9d6_WP_20140216_022.jpeg

The entire desk is turned over on top of the acrylic top, with protective film removed from 3M VHB tape.

342365e5_WP_20140216_027.jpeg

Flame polished edges looking good... plywood edges, not so much! (soon to be fixed).

24f90d5c_WP_20140216_028.jpeg

The set screws are loosened and desk lifted off acrylic top, leaving the custom aluminum fittings adhered to it. I missed one fitting because I forgot to peel back the protective film on the acrylic in that particular spot, but easily added it when placing the acrylic top back on the desk.

6e42bf1c_WP_20140216_030.jpeg

The acrylic top is placed on the desk in the upright position. I didn't want to move the two together because the acrylic top is quite heavy.

3a847941_WP_20140216_031.jpeg

3f0f425d_WP_20140216_043.jpeg
post #36 of 146
Quote:
Originally Posted by hingfdiuh View Post

I had to resist the urge to peel the protective film off of the acrylic top.

lol I know exactly what you mean! biggrin.gif

I like the aluminum mounting blocks, and the method of attaching the top to the desk. Sort of floats that way. Gotta love that 3M 4010 Tape. Such useful stuff, that is thumb.gif
post #37 of 146
Thread Starter 
Update

This weekend I began sanding and adding putty to fill in the cracks, holes, and deformities in the plywood. The wood does not align on the back edge, and will require multiple passes of sanding and filling to build up a smooth transition. Not much eye-candy during this stage in regards to photos, but am hoping to start painting this thing on March 8th.


Photos

(Click to show)

559d8e57_WP_20140222_001.jpeg

I used Flex n Fill spackling paste for its flexible + sandable properties, 120/220 grit sandpaper, putty knife, and will eventually apply primer and plastidip.

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The back edge will require a 6" width of built up putty. I couldn't do it all at once because it would take forever to dry and it has the consistency of toothpaste which makes it difficult to work with in large blotches.

5b397bc4_WP_20140223_010.jpeg

Another beautiful day in Napa.
post #38 of 146
Thread Starter 
Update

There was much more sanding and priming work needing done than I originally thought. I have completed most of it, and while the photos below don't show the top being primed I was able to get to that as well. Next weekend I really hope I can finish prepping for paint. I acquired a piece of sign-white acrylic for the insert and couldn't help but peel the protective film back a bit. This project is taking much longer than I originally thought but am making steady progress!


Photos

(Click to show)

b6f59354_WP_20140308_001.jpeg

Sign-white acrylic inlay. This will eventually be illuminated from below with LED.

933f9709_WP_20140309_003.jpeg

This primer goes on thick and can be wet sanded for an ultra-smooth finish.

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Although this and the following photos don't show the top primed, I did actually get to put on the first layer.

bacdb84e_WP_20140309_005.jpeg

Some pieces of the desk don't quite line up, as you can see above. Most of these are below and in the back, so I can live with it.

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8123065

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post #39 of 146
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Insert Name Here
(14 items)
 
  
CPUMotherboardGraphicsRAM
6700k Asus Maximus VIII Hero Gigabyte Aorus Xtreme 1080ti Corsair LPX 2x8GB 3200c16 
Hard DriveHard DriveCoolingOS
Old Seagate HDD Samsung 850 EVO Thermalright Silver Arrow SB-E SE Windows 7 Home Premium 64 bit 
MonitorKeyboardPowerCase
Asus PG258Q (240hz + Gsync) WASDKeyboards.com v1 semi custom w/ mx browns, ... Superflower Golden Green HX550 Air540 
MouseMouse Pad
Logitech G Pro Qck+ 
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post #40 of 146
Didn't know Zinsser made primer, nice. I use their shellac a lot.

Nice progress, can't wait to see it all painted up!
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