Workstation Storage Case

Instructions

Fixture Setup --------------- - Apply the ShaperTape to the 1/2" plywood. I applied it parallel to the long side. - Place the plywood on the supports. Clamp or tape as necessary. - Scan the tape side-to-side along the short side of the plywood, and move backwards along the long side. ** Make sure to create a grid before cutting! ** - Create a 29.75" x 16" rectangle. Position it centered side-to-side and an inch or two from the bottom. - Cut it out with an inside cut. Foam Setup -------------- - Cut a 29.75" x 16" rectangle out of MDF (outside cut). - Tape the MDF to the foam. - Cut around the MDF with a hand saw. - Use a flush trim router bit to trim the foam to the exact dimensions of the MDF. - Repeat for each sheet of foam. Preparing to Cut ------------------ - Insert the foam into the fixture. Use shims as necessary to make the foam flush with the fixture. - Apply ShaperTape to the foam. - Use the "Add to Scan" feature to add the new ShaperTape to the workspace. Note that only existing tape is used as reference during this process, so you may need to repeat this step multiple times to capture all the new tape. - Rename the new workspace. - Add the correct design to the workspace. You will need to rotate it 90 degrees to align it with the foam. The depth dimensions should be upright. Bottom Foam Layer ---------------------- ** Follow the "Preparing to Cut" steps ** - Cut the foam outline to 1" depth (outside cut). - Apply double-sided tape to the foam so it doesn't shift while cutting. - Flip the foam side-to-side. ** Repeat the "Preparing to Cut" steps ** - Cut the foam outline to 1" depth (outside cut). - Cut the spoilboard storage outline (inside cut). - Pocket the spoilboard storage (on-line cut). You'll need to do multiple passes, so make sure not to cut too many lines before going back to do the second pass at full depth. - Pocket the shelf. I adjusted the outline offset (inside cut) and worked my way from the inside out. - Cut the shelf outline (inside cut). - Repeat for each shelf path in increasing depth. - Remove the foam and cut the bottom edge to a 20 degree angle from the bottom. I set my table saw to 70 degrees and ran the foam through on its edge. Middle Foam Layer --------------------- ** Follow the "Preparing to Cut" steps ** - Cut the foam outline to 1" depth (outside cut). - Cut the spoilboard storage outline (inside cut). - Pocket the spoilboard storage (on-line cut). - Cut the shelf outline (inside cut). - Pocket the shelf (on-line cut). You don't need to pocket the area without lines since it will be cut through from the other side. - Apply double-sided tape to the foam so it doesn't shift while cutting. - Flip the foam side-to-side. ** Repeat the "Preparing to Cut" steps ** - Cut the foam outline to 1" depth (outside cut). - Cut the item paths, working from bottom to top. Make sure to cut the outline (inside cut) first and pocket second for the larger items. Top Foam Layer ------------------ ** Follow the "Preparing to Cut" steps ** - Cut the foam outline to 1" depth (outside cut). - Cut the Workstation attachment face outline (thin strip on left) to 1". You don't need to pocket it since it will be cut through from the other side. - Cut the item paths, working from bottom to top. Make sure to cut the outline (inside cut) first and pocket (on-line cut) second for the larger items. - Apply double-sided tape to the foam so it doesn't shift while cutting. - Flip the foam side-to-side. ** Repeat the "Preparing to Cut" steps ** - Cut the foam outline to 1" depth (outside cut). - Cut the Workstation attachment face outline (thin strip on right) to 1". - Cut the finger pull outlines (inside cut). Remember to cut it in multiple passes. - Pocket the finger pulls. - Cut the Workstation body outline (inside cut). - Pocket the Workstation body (on-line cut). Lid Foam ---------- - Trim the eggcrate foam to 14.5" x 26.375" (I used sharp scissors). - Test fit the foam and trim any pieces that extend above the edge. - Use an adhesive to attach the foam to the lid. I used some Scotch velcro squares.