Backbox Cutlist, measurements and details

We've finished the cutlist and tomorrow we'll go and see the carpenter for MDF, wood and other fun stuff like hinges.

I really like explosion drawings, so I couldn't help but make one. Besides it reveals how many small parts are used for the mounting.

Explosion drawing

Here's the preliminary cutlist. It might change, depending on the size of the hinges. We don't have any hinges at home, so we'll have a look at them tomorrow at the carpentry store and adjust it on the fly if necessary. In that case we'll post an update here of course. 

The hinges are 3mm high, so to be sure, we left 4mm space. 

All 16mm parts for the backbox

All 20mm x 30mm and 30mm x 40mm wood bar pieces for the monitor mount including the support beams, the locking mechanism for the backglass monitor mount and of course the DMD mount

30mm x 40mm and 20x30mm parts

All 20mm x 20mm wood bar pieces for the DMD mounting stand and of course the wood locks themselves. 

20mm x 20mm parts

And last, but not least, the 26mm high speaker stand plates, so the speakers will we centered in the holes from the speaker/dmd panel. They don't have to be MDF, we'll ask for any left-over wood pieces tomorrow that we can use.

Speaker stands

We created detail views for any wood piece that has holes or where anything needs to be cut out. 

Let's start with the speaker panel. We tried to stick closely to the original Williams speakerpanel, but as our cab's gonna be a custom one, so will be the speaker panel.

Speaker Panel

The bottom panel will have a hole of the same size for the 19" DMD monitor as the cab. 

Bottom panel

The small beam at the top of the backside will have a few holes for air inlet which will be supported by an exhaust fan in the bottom area of the backbox door. Don't look for a hole for the fan, as we don't have bought one yet, so we don't have the measurements. It is also needed for the hinges that will allow us to open the top panel.

Top element

That's it for the backbox part. Now let's have a look at the monitor mounts.  The LG 32LB56's mounting features holes for M6 screws with 200mm distance to each other. The TV will be hold in place by 2mm thick 30mm x 30mm aluminium brackets, so we'll have to cut out a path for them. As we don't know for sure if the countersink for the screws will be deep enough, respectively if it's possible at all for us to countersink them, it's gonna be 3mm deep. It'll better to have 1mm space for the screwhead if the countersink isn't working out.

Backglass monitor mounting rail

There are additional counterparts for the locking mechanism, where the monitor can latch in and will be locked in place. This parts will be screwed against the wall of the backbox. For more details see the last post. 

Backglass monitor mount counterpart

The wooden "locks" themselves will be made out of 20mm x 20mm wood. They're smaller than the wood bar they're mounted at so they can rotate around their pivot point without any hassle.

The wooden locks

The mounting rails for the DMD will consist of 2 pieces of different length, as one will overlap the hole for the DMD monitor. The 19" Samsung Syncmaster 901B monitor features holes for M4 screws with 100mm distance to each other. 

Upper mounting rail for the DMD Monitor

Lower mounting rail for the DMD Monitor