Carolina Garrison

Okay here is a build thread for the Tie Fighter Pilot chest box with top and bottom construction.

First start by trimming any excess flashing from the bottom of the boxes. Mark exactly 3in down from the angled Edge on the flat surface of the top box on the front and back side trim straight line and sand the raw Edge. If you have a belt sander you can use that if not you can just use a flat piece of sandpaper on a flat surface. Leave at least about three quarters of an inch from the rolled edge of the bottom box for overlap Construction surface to add adhesive to.

Sent from my SM-G935V using Tapatalk

If you are going to cut an access out of the back of the box go ahead and do so now.

This will also Aid in the construction of the box. Sand Inside Edge of the top box and about a half inch of the top edge of the bottom box add adhesive to the front and back of the box only and fasten them together with clamps until the glue dries.

You can use either E6000, Super Glue, ABS cement, or I have been using this quick hold glue from the craft section. dries crystal clear and grabs very fast.

Line the topbox up along the rolled edge of the bottom box.

Sent from my SM-G935V using Tapatalk

While you are waiting for the glue to dry on the box go ahead and start to trim out the donuts. I always like to do my rough trimming and trim off any flashing with the larger pair of tin snips.

I like to think of these four Donuts as a family. Two adults and two children. The adults are taller than the children so I Mark 2 out at roughly three quarters of an inch thick and then I Mark 2 out at roughly 1/2 inch thick. I then use my lexan modeling scissors to trim the donuts as close to the lines as possible. I then mate them together on a bench while I sand them meticulously to try to keep them at the same height. Two large ones and two small ones. Double-checking each pair to the next as I send them perfectly flat.

Sent from my SM-G935V using Tapatalk

The two adult Donuts get one and a quarter inch holes cut out of the middle of the donut. I cut them out first with a large drill bit and then Dremel the rest out just a little bit at a time until I can fit the circumference of the hose comfortably.

Sent from my SM-G935V using Tapatalk

Next we are going to use some scrap plastic to build side gussets for the chest box. I use the chest box itself to Mark out on a sheet of plastic the size and shape of the gusset I need. I then trim them down until they fit inside of the Box flush and attached with adhesive and hold with magnets.

I also cut some strips about five eighths of an inch wide by 6 in long to help attach the adult Donuts.

I then bend and fit u-shaped brackets down inside the adult donuts and use that to attach firmly and flat to the chest box. You see I drill a hole in the center of the bracket and then through the gusset., and bolt to chest box.

The bottom smaller Donuts just have a hole drilled through the center and I use a bolt going through the gear sprocket, the small donut and in through the side gusset of the box.

Sent from my SM-G935V using Tapatalk