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BUILDING
A MAGNETIZED ARMY DISPLAY BASE
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Click the images
to see larger versions. |
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Fitting the MDF Hardboard.
Much like when you cut the piece of foamcore to fit
the frame, the same must be done with a sheet of 3/16"-thick
MDF "Masonite" hardboard. Carefully measure
and then cut out your piece with a table saw or jigsaw.
If you lack a table saw like most folks, there's still
hope. When you go to pick up the MDF hardboard at a home-improvement
store or whatever, you can ask around for a bit of help.
Nine times out of 10, someone will be glad to cut the
wood to your dimensions. You might have to do some sanding
to get the hardboard to fit snugly. Grab some sandpaper
and get to work if this is the case. Elbow grease (or
a belt sander!) will do the job. Once the hardboard fits,
mark it with an arrow just like you did the foamcore to
help denote the exact way the hardboard should fit within
the frame. |
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Slap the Support Frame Together.
You should have a few feet of 1/2" x 3/4"
pine trim in your possession. You'll need enough to make
a support frame within the main frame that you will attach
to the hardboard. Yeah, it's sounds confusing, but bear
with me here. Pine trim is pretty cheap, so get a foot
or so more than you really need in case of mistakes. Now,
carefully measure the inside of the frame and cut four
pieces of trim to fit snugly within the frame. Remember
to subtract the width of the trim (3/4") when measuring
out the two "side" pieces. You want to end up
with the trim being 1/2" thick, not 3/4". In
other words, just make sure the the "fat" side
of the wood lies down on the hardboard. Once the pieces
fit in the frame, take em' out, place em' on a flat surface,
and use a staple gun with an L-Square to connect 'em. |
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Attach the Support Frame.
Make sure your newly created support frame still fits
within the main frame right on top of the hardboard and
foamcore. Like the foamcore and hardboard before it, mark
the support frame so you know exactly where it is supposed
to sit within the main frame. Pop out all the contents
of the frame and place it aside for now. Carefully line
up the support frame with the back side of the hardboard
so that all the markings meet up as if they were within
the frame. Screw the support frame onto the hardboard
with 5/8" wood screws. Try to find slimmer screws
or pre-drill your holes to keep the wood from splitting. |
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Complete the "Sandwich."
Seat the support frame and hardboard into the main
frame to complete the "sandwich" of various
materials. Flip the main frame over, make sure everything
is pushed in and lined up, and then use the staple gun
to attach the foamcore for good. Staple strategically,
especially in the corners and near the edges. The staples
will keep the foamcore in place and stop it from warping
when the glue and sand dries later. Also, the sand will
cover up the staples, so don't worry about 'em from a
cosmetic sense. |
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Start Layin' Down Fenders.
With the inner "sandwich" all done, break out
the pile of fender washers. Apply a decent amount of super
glue to each exposed circle, press a washer into place,
hold for a few seconds, and move to the next vacant spot.
Keep goin' until the foamcore gaps are filled with washers.
Due to the massive amount of fumes you'll be generating,
it might be wise to do this step outdoors, or at least
in a well-ventilated room with windows. After all, no
one wants to wake up on the floor after an unknown amount
of time covered in glue, fender washers, and dirt. |
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