DK build thread

Chassis back today via Parcel motel,
will try test it later if I have time but no doubt its working!

Rang my uncle too.(the cabinet maker)
Decided to go with high quality 15mm ply keeping with an original.
With a solid CP and solid timber for the monitor frame.

The ply will all need to be filled and sanded to cover the grain.
Apparently the grain will always show through even after primer and PU paint.

3 sheets of ply at about 55e a pop!
should have money to start it by the end of the month

Yep 55 a pop or 38 for mdf,
Might as well do it properly now as I've spared no expense on the rest of the stuff.

I have the replica nintendo t-molding from mikes arcade.
its 5/8" thats 15.8mm in real money.
might be a tiny lip on each side.
should be ok tho.

Build starting tomorrow week!
I've decided Im going to make 2 panels,
one DK replica (obviously )and 1 shump panel with extra buttons.

Going to put one of these under the CP and wire the Jamma harness to it


The 2 panels will be wired to the appropriate plugs for quick swap outs!
Might make a 3/4th blank panel while Im at it for future plans.

Worked on this all day,
Didn't think I had a lot to do but turns out I did and a few bits took ages.

Step 7:
The back.
The back has 3 bits,top bit,bottom bit and door.
Straight forward enough just had to make a few cut outs to match the original.
Mark out your cuts,


Box off your lines and use a router to cut them out.Far better job than a jigsaw.


and this is your finished cut,as you can the cut is lovely!


Step 8:
I drilled the CP and did some routing to let the stick recess and test fitted the latches.


Step 9:
Back to that speaker grill.
So I found out I should of used a 8mm slot cutter for this.
I didnt have one and couldn't get one today so I used a 6.3mm
I made a gig up on the bench for routing and marked out the lines


I actually made a balls of it the second time so ended up doing a third one!
took ages but it was worth it in the end.

Small bit of filling to fix a few chips.


After sanding.Very happy with this


Step 10:
Stick all the bits together


Step 11:
This is the bit I was dreading.
The lower bezel/cp timber.
This is made out a massive lump of birch.
This is a cross section of it.


As you can see the CP slots into this and the bottom of the bezel so it was a bit of a bastard to get right but luckily my uncle is a pro and wasnt phased by it.
He made this part
i was going to strengthen the lower bit but there was no need to in the end.
Also the top of the CP needs to be flattened off to fit in.
This was a bastard of a job and again my uncle did this on the panel saw.

here it is installed.


At this stage I test fitted all the brackets and the plastics.
All looked 100%.
I forgot to take a pic tho!

Step 11:
Paint!
Base coat on .



And thats it for the moment!
I've ran into a problem and another possible one.
I havent got the right slot cutter for the Tmolding.
cant paint until the slot is cut !
And I dont want any grain to show through the paint so Im not sure if I have to use a spray filler on it first and sand it all down so going to shoot some blue onto it during the week and see where Im at.

So deffo wont be painting till next saturday !

Well I ordered the slot cutter and shank.
35 poxy euro delivered from UK.
Should be the last expense in this project............
except a marquee light!