On to the 2nd Chapter in this never ending quest to achieve elusive perfection! Yeah RIGHT!!!
I left off with the decision to redesign the airflow dynamic of the booth from a cross draft to a down draft. Man...if I only knew what work I was actually creating for myself.
In a display of what can only be one-up-man-ship of oneself I decided to cut the plenum using some more of that nice 1/4 ply I
liberated from work. Except I decided that I could make it better cutting more notches and tabs in the individual pieces to add more structural stiffness. Now there are any number of other tools (myself included) and jigs out there that could do this job better and faster. I alas am only armed with my trusty pencil, 36" straight edge, and a very ravenous Black & Decker Jigsaw. So after some deep meditation and aligning my chi with the planets I had at it.
I marked out the pieces with the tabs and notches the night before. Just looking at what I'd done I knew I was jumping in deep.
I also marked the opening on the bottom of the booth...then, after a sleep, the very next morning I took a big breath & cut it out.
No turning back now....I cut out the four sides and the plenum bottom...feeling like I was making a large jigsaw puzzle out of wood. :? I cannot express how tedious this became by the end. However, care and patience was needed otherwise all my hard work would be for naught.
I did do a test fit, and filed some of the tabs and notches to get the desired fit. However I was pleased with how well it all meshed together. Some shots of gluing, assembly and clamps...
And after much gluing and clamping, viola! I even cut an 8" x 7" patch which I simply bolted to the back to cover the hole cut for the Axial Fan.
I'll get my new blower fan on Monday. Until then, feedback, comments and drunken insults are always welcome!