New project

[Crazyraceguy]

I have been working on parts for a couple of days, without much assembly to see yet. The faceframe has 33 openings, eventually having glass fronts and LED strips in a groove on the underside.
The White Oak parts will go to the finish dept tomorrow, after some more joinery. It's all Dominos for the frame itself, but it will get splines to attach the whole unit to the sides/partitions.
The plywood jig has a spring-loaded stop on one end. It traps the part in place and serves as a spacer for the paddles on the DF500 too. The spacing is all equal, so the part just reverses in the jig and gets cut from both sides.
I got interrupted for a rush job today, so not much progress. Tomorrow, I hope to finish the square holes for the LED track, but I won't be installing it. That gets done by others, on-site. I'm never a big fan of that, but the company doesn't want the headache. Lights, especially LEDs always seem to be a problem. It's the same cheap junk, they work fine in the beginning and develop problems later, when access is limited.

 

[Crazyraceguy]

More pics, still no assembly though. This is part of the laminate pieces, which fit behind the faceframe, plus the jig for the square holes. That becomes the path for the light strips.

 

[squall_line]

Did you use your Shaper + Plate to make the jig for the square holes?  Presumably the jig with a dedicated router is faster than the Shaper for batching out large quantities like that.

 

[Crazyraceguy]

Yes [member=75217]squall_line[/member] I made the squares with the "on tool" capability. Once created that way, it is repeatable, as long as the parts are registered that same way. So, I made a duplicate, which is on the other side of that jig.
The parts are 1 1/2" thick, which is way too much to route in a whole that small, plus laminate on both sides. Routing from both sides helps with this.
I made the jig holes to accommodate the Makita. It is set-up with the closest off-set. (1/4" up-cut in a 3/8" collar) There were only 11 of them to do, so I let it go, but it would have been far better to swap to an OF1010. The extraction was virtually non-existent on the Makita. The shroud was an after-thought. It  "looks" similar to the Festool, but that's about it. They try to pull from too high on the base and squeeze the opening down too much. It was obviously an add-on, rather than designed in, and it shows.
A small bit in a small collar with realistically no make-up air, didn't give it much of a chance though?
I ended up plunging the corners of one, switching to the other hole and using the bluetooth of the CT to clear the first. Back and forth, flip over and go again.

Origin is a fantastic addition to what I do, but I don't consider it a production machine. One-offs, inlays, hardware pockets, templates, it does a lot. However, I will always make a template for something and use another router, if possible.
In this case, since the holes are not centered, turning it over would have meant a different pattern.
It would have been slower.... and introduced the possibility of me screwing it up.

 

[Crazyraceguy]

The parts came back from the finishing department yesterday, so I had some time to start the assembly.
All of the splined side parts were glued to their respective face frame. The whole lot was assembled today, then attached to the main structure. There is an LED chase through the whole thing, glass in each opening.

 

[rvieceli]

very very nicely done.

Ron

 

[Crazyraceguy]

Thanks Ron. It turned out nice, even though it was quite a glue-up challenge. I spent over 3 hours, gluing it in sections, then combining them.
I just wish they had spec'd rift-sawn white Oak. The grain match to the laminate would be closer.

 

[Crazyraceguy]

The glass came in after I already moved it over to the shipping/storage area. They will have to be installed in the field anyway. Test fit one piece.

This is just the beginning of a large job, plenty more to come. It might be quite a while before the installation starts.