Poster Ligh Box: - The Box

I got Started on construction today.

How do you draw a straight line with a T square that isn't square?

I marked out my sidewalls, inner and outer walls, using not my crooked T square but my measuring tape. I ended up using the T square to draw lines from one point to the next by flipping it over so the T wouldn't catch on the medium.

 Cutting time, Just like with drawing I can't cut a straight line. Using a large board as I guide I cut out all the sidewalls. Sanded the edges with a reusable sanding block, removing and camphor that I created and evened everything out.

 
Gorilla Glue! Man this stuff is crazy. It's bit of a pain but works like a champ. I was looking for something stronger than Elmer's glue that can be used on foam. This glue "Is Foam" well sort of. It looks and feels like honey, doesn't smell like honey though. First you dampen one side of what ever your about to glue, then apply the glue, recommend lightly, wait a few minutes, then stick your stuff together. Soon the glue will start to foam up and squeeze out of what ever you glued together if you used too much. It very strong yet still flexible after about 30 minutes. 

I picked up a corner clamp for $3 at Harbor freight today, It made all the difference in feeling like I was trucking right along vs being frustrated and ready to throw everything in the trash. Gluing the corners of the outer wall together was a snap. I also taped the corners up with masking tape. After I taped up the second corner I thought better Of my choice of tape, removed the masking tape and applied some painters tape. Smartest decision I made all day. as the masking tape wanted to remove the poster board off of the foam core when I pulled it off. so glad I didn't wait longer than I did to make the change.

While waiting for the glue to dry on my frame, I plotted and cut out my back wall. this is the first place my thinking wasn't actually straight. I neglected to account for 1/4" of the width of the back piece.

No matter I'm a Master Genus! As I attached the plexi glass supports to the inside walls, I was able to glue the bottom to them and to the outer frame all in the same swift move. Disaster averted.

Next step, Sand down the excess foam, I mean glue. Using my handy sanding block, It didn't take long to clean up the mess made by the ever expanding glue. I also cleaned up all the edges with the sanding block.

Finished with all the glue and mess it created.

Now time for paint.This Fusion stuff is great. A few coats of black and all done for the evening. I just painted the sides and a portion of the back of the box black.

there you have it. the base is complete, It's light and sturdy. Now I have to wait until I get the rest of my supplies before I can continue. I should have more by this Friday or Saturday.

Poster Light Box: - The Plans

I have decided on materials I plan on using.

As I mentioned I am going to use foam board as the base material for my box.

I found 2 sheets 40"X60" foam board at Hobby Lobby today for $9.95 each.

I also picked up a 4oz bottle of Gorilla Glue for $9.99 @ Hobby Lobby. Chose it due to it's ability to glue foam without melting it..

Other things I am going to need before I have completed this project:

2 pieces of UV filtering Plexiglas

24' of LED rope lights

Aluminum foil or other pliable reflective material.

Mirror hanging kit

1/4" aluminum angle

spray paint of choice

clear coat

First things first.
I have compiled a rough sketch of my design. It's not to scale but the measurements should be correct.

Poster Light Box

Starting a new project today. I have always wanted on of the Back lit Poster boxes that you see at the theater. Now I have decided to make my own.

I have researched across the Internet for the last 2 days. I have seen the extreme prices that are charged by companies for manufactured poster light boxes ($400-$1500). I have also seen lots of great work with wood at a much cheaper cost ($150-$250), but I wanted something lighter due to all of my moving around.

after some considerable thought on the matter, I have decided to use Foam board, or foam core poster board, which ever you like to call it. Using peaces and parts of multiple peoples designs, I am going to construct a beautiful functioning box at a fraction of the cost of some of the wood boxes I have seen.

As I make progress I will document it all here.

And...Here...We...Go!