CuttingtheInsulationFoam

Ifyouarecuttingusingastandardtablesaw,Ifoundthatitiseasiertocutthelarge4x8sheet
intosectionsslightlylargerthantheultimatepaneldimensions.Thisbothmakeseachindividual
paneleasiertoworkwithandprovidesacleanoppositetothefinalcutwidth.

Oncethesheetshasbeencutintotheapproximatepaneldimensions,youcanthencutthe
actualdimensionsintheCAD.

FrontPanel:25.6875x30.625
BackPanel:25.6875x30.625
SidePanel:19.375x30.625
TopPanel:21.375x25.6875

Nextyouneedtocutthewindowintothefrontpanel.Icreatedajigbutarulerworksjustfine.
Fromtheupperleftcornerastheoriginofacartesiansystem,measure3.25inthe+xdirection
and3.1875intheydirection.Thiswillbetheupperleftcornerofthewindow.Thedimensions
ofthewindoware18.75wideby19.3125tall.Seepicturebelowforrelativeorientationif
confused.Cutoutthewindowanddiscardthescrap.


FrontPanel,BackPanel,SidePanel,andTopPanel

GluingTogethertheFoamBox

*FollowthevideoandconsulttheCADforbettervisualsonhowtoassemblethebox

Usinghotglue,laydownacontinuouszigzagginglineaboutaninchwidealongoneofthe
edgestobeglued.

Firmlypushthematingpanelstogetherandholdwhilethegluedries.Thefrontandback
panelsshouldbeontheoutermostface,whilethesidepanelsitsbetweenthefrontandback
panels.Thetoppanelshouldbeplacedonthetopofthefront,side,andbackpanels.

TapingtheEdges

Oncetheboxhasbeengluedtogether,theexposededgeswheretheyellowinsulationfoam
canbeseenneedtobecoveredup.Usingfoiltape,coverallexposededgessothatnofoam
canbeseen.

CuttingtheCorruplast

Becausethepaneldimensionsofthecorruplastarelargerthanthefoam,cuttingapproximate
dimensionsisnotpossible.Infact,thewidthdimensionsofthepanelsaddupperfectlyto8or
96.Socuttingalongtheexactlinesistheonlywaytomakeuseofthewholepanel.Note,due
tothewidthofthesawblade,eachpanelwillbemissingbetween1/16ofmaterial.This
hasnotbeenaproblemforusthough.

Theexactdimensionsareasfollows:

FrontPanel:26.625x32.5625
BackPanel:26.625x32.5625
SidePanel:21.375x32.5625
TopPanel:21.375x26.4375

Likethefoam,nextyouneedtocutthewindowintothefrontpanel.Icreatedajigforthisas
wellbutarulerworksjustfine.Fromtheupperleftcornerastheoriginofacartesiansystem,
measure3.5inthe+xdirectionand3.875intheydirection.Thiswillbetheupperleftcorner
ofthewindow.Thedimensionsofthewindoware19.75wideby20.3125tall.Cutoutthe
windowanddiscardthescrap.

GluingtheCorruplasttotheFoamBox

WemakeuseofLoctitesprayadhesivewiththewebspraynozzlefeaturetogetgoodcoverage.


Thedirectionsonthebottlespecifythateachcomponentgettwocoatsofadhesive,spaced
about25minapart.Thegeneralprocedureinvolvedapplyingacoatsofadhesivetoboththe
corruplastandfoamthencarefullystickingthecorruplastpanelsontothefoambox.

RefertotheCADmodelandvideotoseeorientationofthecorruplastsheetsandprocedureof
gluing.Therewillbealipleftonthebottomleftsideedgesofthefoambox.Thisissothat
corruplastcoversthePVCsheetsforaestheticpurposes.Whenapplyingadhesive,becareful
nottogettooclosetothehangingedge.Thegluedriesnontackysoitisntmuchofaproblem
ifalittlegluegetsontheseregions.Foralignmentpurposes,seethatthecorruplastcreatesa
~.5rimaroundthecenterwindow.Thiswillbewhereweatherstrippinggoes.

CuttingtheWindowPlate

Usingatablesaw,cutasheetofpolycarbonateto19.75x30.3125.Roundtheedgeswith
awoodfileandsetaside.Thiswillbethewindowplate.

CreatingtheWindowSealandMagneticConnection

Usingthedoublesidedhighbondfoamtape,stacktwoofthe0.75neodymiumdiskmagnets
andtapeonestackoneachofthecornersofthewindow,andinthemiddleofeachofthe
edgesofthewindow.Makesureallthemagnetsarethesamepolarityfacingoutward.

Placestripsofweatherstrippingbetweenthemagnetsinthe.5gapleftbythecorruplast.

Finally,foamtapemagnetstotheoutsidefaceofthewindowplatebyaligningthewindowplate
withthewindowintheshell,andplacingthemagnetsoverthestacksbelow.

WindowOff WindowOn