Art Deco Zenith 5-s-29 Radio Case Mod

Edge Cutouts

The cutouts on the top edges were something that concerned me from the start as I wasn't sure how I was going to do them given the curve of the edge. The Dremel cuttting wheel again did the trick. I again set up a jig so that I could cut the grooves consistently across the sides and front and get them straight. I would get the depth on my Black and Decker Dremel clone, and cut the slots on all three sides so that they would match. I started with the bottom slot and worked my way up.


With a little careful marking and freehanding on the corners, here is the result:

Gluing

I drilled out all of the holes for dowel rods on the ends, and glued the main pieces together. It takes this step to realize why you need all of those different sizes and numbers of clamps.


Here is a pic of the case all glued together.


I spent a good bit of time bending, adjusting, etc. to get the motherboard tray mounted to the radiator mount/air chamber and it all mounted into the case as intended. I used an old MB and GPU to test mount with to make sure the MB tray and back panel line up right. It of course isn't staying there yet since there is more sanding to do and it has to still be stained, but these had to be placed to make sure it is all fitting as planned, and so that I could make the reservoir mounts.