Haribon72

Oh man... the emperor wife was displeased with my bathroom time. HAHAHAHAHAHHAHAAH!!! Thanks Rick! Can't wait to see your boxes bro... and remember do it in the bathroom!

Thank you Tim! Yes, they were paper thin at many points. Its impossible to get sharp edges perfect. I just hope our deployment officer will "not" be super strict on those sharp edges! Otherwise, i'm heading over to Home Depot and making some "wooden" boxes!

Why the blue tape on the ab plate? I will be filling in the gaps to my boxes by using Apoxy Sculpt (AS). I will let it cure over night. The next day, I will remove each box and sand it down to a perfect fit. I didn't want the (AS) to harden into the ab plate. Any suggestions, please let me now. I'm aware we need to have seam lines to each box for accuracy.

Installing the New Shins to the Abs Plate If you're wondering what's up with the blue tape, I will explain later. For now, here are the pictures of the new shins - all cured and ready for assembly. Clamping it down. I used Weld-On ABS cement as my adhesive to secure the new shins. We will be using Apoxy Sculpt later to cover of the seam lines.

Insert the bolt through the ab plate hole, apply ABS cement, and then carefully set the box. I waited a few then placed the box in a holding box to set overnight. Box # 5 was the challenging one.

Here are my bolt and nut holders. All are held down with Weld-On ABS Cement to a scrap backer plate.

Took me about three hours (including the OCD moments) to finish up. And that's just the sharp edges attempt. Let me know what you think. Yes, some of it is not 100% super super sharp, but hey.... we're working with plastic formed boxes with smooth edges. Hopefully, its already at a level 3 achievement. Some of the lighting is drowning out my sharp edges.

Here are some work pictures . . .

After a couple hours of sanding.....sanding...and more sanding...... I can see why this is going to be an OCD moment. No matter how hard you try to get the "perfect sharp edges", some of my plastic boxes did not have enough plastic meat. In this picture, i'm getting near the "paper thin" point. And in some cases... I already got to the breaking point. No worries, I will reinforce it with ABS cement.

Here's a picture of the difference between two boxes. Still sanding away.

ABS Boxes Using the information provided by Brian (SolderMaster). I will be using two types of sandpaper. First, 3M BlasterPro P120 325U (available at Lowes) - used as a rough sanding to get the edges started. Second, 3M WetorDry TRI-M-ITE 413Q 400 CES (avaliable at Home Depot) - used to smooth out boxes and bring out the sharp edges.

Here are the bathroom pictures! hahahhaha!!!

dude... did you finish the abs boxes yet?

Hahahha! My wife got the shirt at the San Francisco Pistahan event last year. I'll let you know if the vendor is selling again this year in August!

Lock the thread Tim. Well said.

Reinforcing the area as instructed by Tony and Alpha troopers. Sloopy reinforcement work. I had to rush because we have guests for next couple evenings. Need to clean up shop and house. I'll be back Thursday everyone!

I'll be sharing a lot on shim work. My diet isn't going very well. On with the show! Working on the inside ab plate (before putting on the side shim work). Marking the center point for each box and then drilling the holes using a Unibit.

Tony.... you laid out the foundation! I'm just following your road to success!

(Place holder)

Inside backer = I used Weld On ABS cement. This will ensure the backers and the shims don't break apart. Experimenting more on other strips / shims.

On the other side, I wanted to experiment. I decided to heat bend the shim for Box # 7. Not the greatest looking, but it was worth the experiment. I custom cut a painters mix stick, heated up the plastic, and then "slam press" the piece into shape.