4ft by 8ft MDF sheets surprisingly heavy. Took me a while to figure out how to get this up onto the cursedly mobile saw horses.
Handy paint pot lid to draw curved edge.
First cut with the saw board and I forgot to set the circular saw blade deeper. Nice groove though!
Curves were jigsawed. Managed to get quite a nice result.
One side cut, now just need to make the piece of wood behind it identical.
Testing the flush trim router bit on an off cut. First time I'd used a router!
Two identical sides!
The slot, by the way, is for the t-molding. You probably don't know what it is, but you probably recognise it - it's the plastic trim that edges off arcade machines and it requires a very specific router bit.
Most significant cock up. This is along the bottom edge of one of the side panels. Didn't have the router levelled when cutting the slot, so it came out too high. It's only on the bottom though, so should be able to cover it up later.
Laying out the structural elements. Really tough to get both pieces identical again.
Wanted the beams to be an MDF thickness from the edge, so created a stepped MDF tool to rest against the edge and make sure everything was aligned properly.
All visible screws are countersunk, to be filled and sanded later.
Structural beams on, both pieces line up.
Attaching the base piece.
Cross beam and the top piece. The top piece had weird angles on the front and back edge. Needed to use the angle function on my circular saw.
It stands (and rolls, on wheels which you can't see)! Okay, this is taken about an hour after I stood it up and it literally all fell apart. Could have cried. Luckily, the screws only pulled out. Turns out the screws I'd used in various places were too short, so I replaced them with longer wood screws and it all seems stable now. Live and learn. I think I'll put more cross beams in to be certain though.
Cutting a big circle is hard. Started off trying to hand router one, but it was way too tough and the results awful. Got better result using a jigsaw very slowly. Used the final one as a template for a flush trim router bit.
