The Radio
Cart

Handtools Workshop CNC

Download the file and change its parametrics to the desired sizes if needed: file download link

1. 

   Get rid of the groove from the file and cut all sheets to size using a handsaw, or ask your local supply store.

   

   Cut sheets to size using a tracksaw, table saw, jig saw.

   

   CNC the file.

   
2. 

   Mark locations for screws and pre drill (diameter of the drill should be 1mm smaller than the screws used), you can space them approximatively 100mm apart and counter sink the holes. For the peg doors, you can use an already made pegboard and screw it to the doors (or anywhere you would like it to be).

   

   Using a router (with a cutting bit the size of the thickness of your planks) rout out all the grooves as shown in the model. Alternatively, you can use dominos or similar dowel techniques as a replacement for the grooves (faster).

   
3. 

   Screw and glue together the inside walls and shelves first.

   

   Assemble glue and clamp the inside walls and shelves to the middle wall.

   
4. 

   Glue and screw inside walls to bottom.

   

   Insert inside walls into the bottom and screw from below (screws will only be visible from the bottom of the cart and add strength).

   
5. 

   Glue and screw the front and the sides.

   

   Glue and clamp the side walls.

   
6. 

   Glue and screw the top.

   

   Glue and clamp the top.

   
7. 

   Glue and clamp the front (speaker side).

   
8. 

   Drill the holes for the door hinges according to the specsheet of the chosen brands. Mount hinges, doors, magnets and any other hardware of your choice. Pre drill holes for the wheels and fix them with bolts and nuts (preferably carriage bolts).

   • Kitchen cabinet hinge (all the doors, except for on top)
   • Top one: invisible hinge, 10mm
   
9. 

   If you counter sinked the drill holes you can fill them with wood filler. Sand and apply finishing of your choice! (Stain/laquer, paint, oil or wax)

   

   Sand and apply finishing of your choice! (Stain/laquer, paint, oil or wax)

Roof instructions

Parts needed for the roof are found on the open structure website.

1. 

   Using a metal saw, cut out the shape of the brackets out of 2mm steel. You can use the open structure grid for dimensions.

   

   Using an angle grinder or metal bandsaw, cut out the shape of the brackets out of 2mm steel. You can use the open structure grid for dimensions.

   

   With the DXF file of the brackets, laser cut them out of 2mm steel.
2. 

   With a 10mm drill, drill out the mounting holes in the brackets.

   

   With a 10mm drill in a drill press, drill out the mounting holes in the brackets.
3. 

   Using a metal saw, cut the 20mm aluminium tubes to size.

   

   Using a miter saw, cut the 20mm aluminium tubes to size.
4. 

   Drill 10mm holes for locking pins in the aluminium tubes.

   

   Using a drill press, drill 10mm holes for locking pins in the aluminium tubes.
5. 

   Using a handsaw, cut the wooden beams to size.

   

   Using a mitre saw, cut the wooden beams to size.
6. 

   Drill 10mm holes in the beams for the mounting brackets.

   

   Using a drill press, drill 10mm holes for the mounting brackets.
7. 

   Drill 20mm holes in the beams for the aluminium tubes.

   

   Drill 20mm holes in the beams for the aluminium tubes.
8. 

   Attach beams together with the mounting brackets using M10 bolts, nuts and washers.