Cheers Guys!

Hiiyah: Awesome! I’m really looking forward to following your build!



Project Update:

I will now destroy this innocent piece of Aluminum (sensitive viewers may want to avert their eyes).




The Aluminum plate that will be used to fabricate PLED structural mount.


The first step is to prepare the internal plate by removing the angled edge – it’s not needed.

Cylindrical Aluminum standoffs will be used to mount the internal plate to the existing TJ07 vertical structure.





Since the closest length is 1” and they’ll need to be shorter, they’ll have to be filed down a bit – more on that later.


We’ll start by cutting the angled edge off the plate with a jigsaw. I’ll secure the plate and freehand cut this sucker.






Sometimes I’ll use a cutting guide but this cut is pretty simple – I’ll take my time so as to avoid a Freudian slip.




Oh no; he didn't just say that...


Ok, enough foolishness... time to get down to business.









Once the cut is done, I’ll clean up the edge with a bastard file and Emory cloth.



The next step is to build a template for the PLED mount holes. For this I’ll use a piece of clear Plexiglas.






I carefully measured the PLED mount holes and created an accurate paper template which I then transferred to the Plexiglas. The next step is to overlay the template onto the plate and lineup the grid with the opening.






Once the plate is marked and triple checked, I’ll drill the PLED mounting holes. No need to show drilling shots – I’m sure you guys know what that looks like.






Since we’re short on available space yet want to use a clean front facade, I’ll oversize the display openings in the internal plate. This will provide the clearance needed by allowing us to countersink the top black portion of the PLED flush with the outer edge of the internal plate - thus gaining the critical 1.5mm needed.





Confusing? I show.


I’ll start by setting up the plate and preparing it for the operation.





Next, I’ll grab my trusty Dremel…





I’ll use the wood as a guide and carefully…





Wait a minute!


Mr. Dremel, you are too puny…

This task calls for pure spinning destruction... the kind that only the RotoZip can provide.




Oh hell’s yeah.


Now that I'm using the RZoD, I really need to make sure the cutting guide is accurate. With the right bit, a RotoZip is pure destructive pleasure but you cannot freehand cut a straight line - unless you're a brain surgeon maybe!




Now we're ready!







Sorry, no live action shots - I can't RotoZip with one hand (well, I probably could but I don't want to end up with one hand!).




One line down, 11 to go…





The first one is done.





All done!



Ok, time for a cigarette (even though I don’t smoke). I’m a simple man of simple pleasures; using the RotoZip is one of them. The one downside is of course the cleanup. While mostly contained, I do find frags as far as 10 feet away.




ShopVac... front and center - Stat!


Next, I’ll countersink the mount holes and test fit the PLED using temp bolts.






I’ll use rubber grommets as spacers for now, these will likely be swapped for nylon spacers later.








That’ll work!







Finally, I’ll lay the facade in place to get an idea of final look.






Well, that’s all for today. The next step is to mount the internal PLED plate to the existing vertical structure and attach the facade. This should complete the mockup and fabrication of the PLED mount - then I can get the measurements needed for the side panel water jet cutting. The next phase will be to design and construct the lower section of the LC loop and then it’s off to powder coating. Somewhere in there lies the new concept that I’m super excited to reveal!

Until then - thanks for looking in.