Sunday, October 14, 2018

Battery Box Harness Part 4

The final part of the battery box harness is the small block at the goes on the bottom. I made these the same way as the top block. I started with a piece of hardwood and cut the notch on the router table. I then cut the pieces to length and angled the sides on my mini belt sander.


To attach the hinge to the rest of the harness I drilled a hole in the end of the harness and the end of the hinge piece and connected them with glue and a small dowel.


I also used a down to connect the hinge to the battery box.


Initially I attached these incorrectly to the batter box. I thought the hinge attached to the front surface of the box so I had drilled the lower set of holes. After looking close are reference pictures I realized that it was supposed to go into the bottom of the half moon part, so I drilled another set of holes there. These holes would have been much easier to drill if I had done it before attaching the half moons. I had to drill these holes a little bigger then the dowel to be able to get the dowel into the hole. I will eventually fill the other holes, and they will be mostly hidden by the harness.


Saturday, October 13, 2018

Battery Box Harness Part 3

In my last post I showed the first part of the hinge, next is the part that mounts to the battery box. This piece was made pretty much the same way as the first one.

I started with a piece of hardwood long enough to make all the parts and also the correct thickness. I laid out the shape of the part and then drilled the hole for the hinge pin. I also cut the width of the finished part using a bandsaw.


Next I used a drum sander to create the round over.


Next I cut the finished thickness on the band saw.



Finally I cut the piece from the piece of wood I started with.


Saturday, October 6, 2018

Battery Box Harness Part 2

The next part of the battery box harness to make is the hinge at the top. I started by cutting some templates for the shape of the hinge pieces.


I started with a piece of hardwood cut to the rough dimensions of the final part and long enough to make all four copies of the part. I then traced the template on the wood being sure to also mark the center of the hole.


Before making any of the cuts I drilled the hole through the part.


Next I cut the rough shape using a jigsaw.


I then used my mini belt sander and files to clean up the cuts.


Next I used a second template to layout the fork shape on the end of the part.


I used a bandsaw to cut the fork.


The bandsaw doesn’t leave the bottom of the cut very clean, so I cleaned it up with a file.


Here is the finished piece.