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Project:Pooyan Boards
Project Started:2/2/2004Project Status:Sold

Goal of Project:
How I reproduce a special piece for a game.
This page just outlines the steps taken to reproduce a speaker board for a Tutankham/Pooyan style Stern slim jim cabinet. The front lip where the Tmolding and the Marquee meet had broken off the original rendering it useless. The parts needed were:
  • 1/2 inch channeling bit
  • 1/4 inch channeling bit
  • Slot Cutting bit (for T molding)
  • 1/4 inch Template cutting bit.
  • First step was to get a piece of matching material wood cut to size.. In this case it was MDF that I got from the scrap pile at Lowes for 50 cents :)
    Next, I reproduced the tongue on both sides of the board that will fit the slot in the cabinet using my 1/2 inch bit.
    The speaker grill slots come next, using a 1/4 inch drill bit I cut pilot holes for the 1/4 inch Template cutting bit to fit through so I can follow the original contours exactly. You don't see it in the picture, but there are 2 C-Clamps holding the two pieces of wood tightly together.
    Next I set up my jig to put the routs for the Marquee and Tmolding to sit in. This was definitely a measure twice, cut once situation :)
    The completed replacement waiting for some paint! In this picture you can actually see the piece of wood that was missing on the original and how it's supposed to be on the reproduction.

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