It's been a long time, but I have an update. Let's get right to it- since we left off last time, I began work on the side window. I began by drawing a template, then using a hobby knife cut out the areas to be marked on the panel.
Then used a sharpie to mark my cuts and got the Dremel and friends ready to party.
For the tighter cuts where Jigsaw and Dremel cutting wheel would be difficult, I set up the router attachment, and used the same tungsten carbide bit as I used for cutting the foam for the bezel.
I stopped to take a break, and realized that I had placed the template sideways!
This is the reason for the delay in updating. I had to come up with a design around the cuts that were already made- luckily not many. I came up with this, sort of a positive/negative space design. I started the Dremel cuts, to set up the jigsaw and router cuts.
And here we have the cuts made, as well as the tools used.
Then there was plenty of filing, grinding, and sanding to do. I won't be using u-channel, so I want to keep the edges as smooth as possible. There were some tight spots that were tough to get at, I had to get creative with the mouse sander and bits of sandpaper to get everything smooth.
And a closer look.
Since I had the sanding stuff out, I figured I would sand the surface for priming. The thin strip that runs above the eyes is a bit uneven, but I think i can even that out with filler putty.
Next up I need to order a power button and figure out where I'm going to put it. I don't think I'm going to go with the traditional spot on the bezel- feel free to chime in with any ideas on this, and thanks for looking