08-03-2012, 11:26 AM
Hi,
Well remembered David; yes I did indeed make some radio back panels a few years ago and the article was published in the Bulletin.
A chum at that time had bought a Philco Peoples set back panel through eBay which I think cost him £27. Unfortunately it never arrived. In desperation he borrowed a back panel and used it to draw around and add all the holes etc onto a piece of 3mm plywood and was going to attempt hand drilling all the holes.
As we spoke I suggested if he bought a sheet of 3mm MDF that I would attempt to make him a pair of back panels as he needed two for his sets.
With the MDF home I set about in the garage and cut out 20 blanks as I wanted to experiment to see if I could make these panels in bulk. I transferred the outer dimension onto a piece of white Conti-plas and very carefully cut this out using the bandsaw. Ten blanks were stacked and the template placed on top then two 6.5mm holes were drilled right through the stack in the waste area. The template holes were then countersunk and the stack firmly secured with two 50mm x 6mm countersunk set screws and nuts.
My Startrite combination woodworking machine is fitted with a shaper and a large rebating head was fitted and adjusted; the stack of MDF blanks had been trimmed leaving 1/4" excess material all round. The machine was very carefully set up to allow the template to act as a guide and stop therefore preventing a serious accident. These shapers are very scary to use and are responsible for the loss of many body parts; A big heavy cutter block spinning at 6,000rpm is just waiting to inflict injury. Keeping both hands well clear of the cutters the stack was gently fed in and it only took a minute or so to trim the ten blanks perfectly to the template size. A second stack of ten was then done. Dust extraction is a must whilst doing such work.
I think there are well in excess of 600 holes in these back panels and no way was I going to attempt to drill a single hole freehand let alone drill all the holes for the 20 panels. Like David; I use jigs wherever possible so I made a jig out of 1/8" thick mild steel. Care was taken in making the jig because any mistake would be duplicated many times; pilot holes were drilled followed by drilling at full size.
Metal Jig.
The jig was taped securely in position on the first stack of blanks and the holes were drilled using the big drill press. These first ten blanks were not perfect because I hadn't realized just how quickly MDF blunts HSS drill bits. The ten panels were acceptable but the second ten were perfect. The Hegner scroll-saw I've just sold was used to cut the various openings and the correct sized Forstner bit drilled the large holes with ease. A going over with the Bosch random orbit sander tidied them up and yes it is possible to produce these back panels in bulk.
Metal jig secured in position with tape and in use.
I found that spraying the panels using Poundland black spray cans gives a pleasing finish as the paint sinks in and dries matt.
I gave my chum 12 of these panels and have given the remaining panels away. I didn't do this to make money but to see if it could be done. Making the 20 panels took a few days but was a very interesting project. My chum also required another back panel for one of his sets and the jig proved just the job once again; I only made a single one of this pattern as the set wasn't a common one. Just in case anyone asks; my chum retained two of the panels for his own sets but has given the remainder away to help others out.
Original and newly completed back panel.
To make one of these peoples set back panels drilling each hole one at a time takes tremendous concentration as one slip and the job is ruined. I can understand you aching for long after Robert having made a back panel this way and credit to both you and David for producing a back panel each; its possible I made 20 of these panels in less time than it took each of you to make one. I do have the advantage of machinery at my disposal but even so I don't want to repeat the exercise again as drilling all those holes was soul destroying even with the jig in position.
Kind regards, Col
Peoples set back panel.
Well remembered David; yes I did indeed make some radio back panels a few years ago and the article was published in the Bulletin.
A chum at that time had bought a Philco Peoples set back panel through eBay which I think cost him £27. Unfortunately it never arrived. In desperation he borrowed a back panel and used it to draw around and add all the holes etc onto a piece of 3mm plywood and was going to attempt hand drilling all the holes.
As we spoke I suggested if he bought a sheet of 3mm MDF that I would attempt to make him a pair of back panels as he needed two for his sets.
With the MDF home I set about in the garage and cut out 20 blanks as I wanted to experiment to see if I could make these panels in bulk. I transferred the outer dimension onto a piece of white Conti-plas and very carefully cut this out using the bandsaw. Ten blanks were stacked and the template placed on top then two 6.5mm holes were drilled right through the stack in the waste area. The template holes were then countersunk and the stack firmly secured with two 50mm x 6mm countersunk set screws and nuts.
My Startrite combination woodworking machine is fitted with a shaper and a large rebating head was fitted and adjusted; the stack of MDF blanks had been trimmed leaving 1/4" excess material all round. The machine was very carefully set up to allow the template to act as a guide and stop therefore preventing a serious accident. These shapers are very scary to use and are responsible for the loss of many body parts; A big heavy cutter block spinning at 6,000rpm is just waiting to inflict injury. Keeping both hands well clear of the cutters the stack was gently fed in and it only took a minute or so to trim the ten blanks perfectly to the template size. A second stack of ten was then done. Dust extraction is a must whilst doing such work.
I think there are well in excess of 600 holes in these back panels and no way was I going to attempt to drill a single hole freehand let alone drill all the holes for the 20 panels. Like David; I use jigs wherever possible so I made a jig out of 1/8" thick mild steel. Care was taken in making the jig because any mistake would be duplicated many times; pilot holes were drilled followed by drilling at full size.
Metal Jig.
The jig was taped securely in position on the first stack of blanks and the holes were drilled using the big drill press. These first ten blanks were not perfect because I hadn't realized just how quickly MDF blunts HSS drill bits. The ten panels were acceptable but the second ten were perfect. The Hegner scroll-saw I've just sold was used to cut the various openings and the correct sized Forstner bit drilled the large holes with ease. A going over with the Bosch random orbit sander tidied them up and yes it is possible to produce these back panels in bulk.
Metal jig secured in position with tape and in use.
I found that spraying the panels using Poundland black spray cans gives a pleasing finish as the paint sinks in and dries matt.
I gave my chum 12 of these panels and have given the remaining panels away. I didn't do this to make money but to see if it could be done. Making the 20 panels took a few days but was a very interesting project. My chum also required another back panel for one of his sets and the jig proved just the job once again; I only made a single one of this pattern as the set wasn't a common one. Just in case anyone asks; my chum retained two of the panels for his own sets but has given the remainder away to help others out.
Original and newly completed back panel.
To make one of these peoples set back panels drilling each hole one at a time takes tremendous concentration as one slip and the job is ruined. I can understand you aching for long after Robert having made a back panel this way and credit to both you and David for producing a back panel each; its possible I made 20 of these panels in less time than it took each of you to make one. I do have the advantage of machinery at my disposal but even so I don't want to repeat the exercise again as drilling all those holes was soul destroying even with the jig in position.
Kind regards, Col
Peoples set back panel.
Happiness is a wreck of a cabinet to restore.
