Bartemus
Ex Member
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I have completed a ZOB build and have been trying them out for the past week. Here are some pictures and comments on the build.
Following the tip from ZYGI, I built the entire thing of MDF. I was able to get pre-veneered MDF for about $13 a sheet from a local bargain shed so the entire build was extraordinarily inexpensive (I think I spend more on paint and stain than the materials).
General comments:
While this build does not involve difficult woodworking (e.g., complex joinery) it does require care and precision. The openings between the chambers of the box and the sliding panel (#7) are only 1/8 and 3/16 inch. Since the box is constructed primarily using the side panels to align the center panels, all of these panels need to be cut precisely square and very close to the right length.
It is worth taking some time to make sure that your table saw, miter guide and other equipment is properly squared and tuned up before making cuts. Since the panels are constructed beginning at one end (with panel #1) and joining the remaining panels in sequence, any errors in length or squareness will tend to accumulate as each new panel is added. Thus, you can come to the last panels in sequence (e.g., #6) and find that the opening is neither straight nor the right size.
It follows that the slots in the side panels also need to be cut at precisely the same height and angle or the gaps will be the wrong size or vary in width. This is almost impossible to do on a table saw. It is better to either make a precise jig for a router or cut the slots by hand and chisel them out.
One approach that helps (though it won’t fix major misalignment) is to wait until panel #5 is in place, then cut #6 to give the proper gap.
Suggestions:
These are some things I found useful during the build. Your mileage may vary.
1. This should be obvious, but make sure that all the interior panels (#1-8) are cut at the same time with the rip fence in the same place. That way you will be sure that they are exactly the same width and will form a box without gaps when joined to the side panels.
2. During glue-up of the last panels (esp. 5, 6, and 8) it is useful to dry fit the sliding panel #7 in place with spacers to set the gaps to the right size. This is shown in the photo. You can then adjust the fit and mark exactly where each panel should be place.
3. If you are using MDF, the slot cut into the side panels makes the long arms very fragile. They can easily break where the slot is cut since there is only about ½ inch of MDF there. In addition to being careful, I think it helps to put a cross-brace near the top. If you look a the photos of the new ZOB produced by Decware, you will see that they are using one there now (though it does not appear in the plans). This also gives an additional attachment point for the front panel.
I’ll try to post more thoughts as they occur.
Cheers, Stuart
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