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.