New Build

[mclund]

Here is the progress from tonight's work.
2014-01-23 18.08.24.jpg
Routing the door openings.
2014-01-23 18.14.40.jpg
material is flipped and prepped for routing door lands.
2014-01-23 18.24.31.jpg
Routing door lands.
2014-01-23 18.27.00.jpg
2014-01-23 18.25.08.jpg
Door lands complete.

[mclund]

LED lights are installed before folding begins.
2014-01-23 18.52.25.jpg
Track, lens cover and lights are cut to length.
2014-01-23 19.03.26.jpg
Track is glued in and wires soldered.
2014-01-23 19.06.13.jpg
completed light assembly.

[mclund]

Now the fun begins. The PVC is heated and folded at the V-grooves.
2014-01-23 19.31.03.jpg
folding the back up.
2014-01-23 19.37.02.jpg
Folding the bottom up.
2014-01-23 19.41.58.jpg
The sides are dropped into place just before the Top is folded down.
2014-01-23 19.47.33.jpg
As the top comes down in the final fold, the wire is guided into a groove cut into the side so it is out of site.
2014-01-23 19.50.39.jpg
Lights on!

Still a bit of work to do before this gets put to use. Doors and final assembly are a couple nights of work.

[psychocircus]

looking awesome and professionally done.

[kelzerman]

Very clean looking!

[knox]

Thanks for taking the time to post the pics and the write up! Looks like a great cage.

[pdomensis]

do you do these one at a time, or do you have an assembly line going?

[Sublimeballs]

How much does a 4x8 sheet cost and where do you get it?

That cage looks incredible! And done all by hand. I wanna give it a go.

[kelzerman]

Originally Posted by Sublimeballs

How much does a 4x8 sheet cost and where do you get it?

That cage looks incredible! And done all by hand. I wanna give it a go.

I think they were getting it at $75 a sheet.

[mclund]

Originally Posted by pdomensis

do you do these one at a time, or do you have an assembly line going?

Most of the cages are single production. The arboreal 2x2 cubes we make 2 at a time. We have been building templates for the last 3 months and are just about at to the point where we can start kicking them out. We can pre-make doors and sides, but the big restraint on mass production would be space. Once you start routing out a sheet you don't want to move it off the work table. This is a hobby for us, we both work demanding jobs and this is really good stress relief.

[mclund]

Originally Posted by kelzerman

I think they were getting it at $75 a sheet.

That is correct. Usually the more you buy the cheaper you can buy it.

[LarryS]

Yes that's in the ballpark, we usually buy ten sheets at a time. Prices vary from time to time also. A single 4 x 8 x 1/2" sheet of black PVCX should run in the $85 range. I think the white is 5 to 10 dollars less per sheet.

If tools are an issue, many plastics suppliers will cut the sheets to size for a reasonable fee. You can build a cage using butt joints and screws with sliding glass doors for a very reasonable price.

Edit - oops Matt and I must have been typing at the same time.

[mclund]

Update. Not much progress tonight, but I am committed to document this from start to finish.

2014-01-28 17.33.20.jpg
The cage is clamped and solvent applied to all joints inside and out.
2014-01-28 18.59.26.jpg
Acrylic is rough cut and placed in "the door-maker". Hinge holes are being drilled.
2014-01-28 19.00.48.jpg
Latch holes are being routed.
2014-01-28 18.58.55.jpg
The door is ready to be routed to size.
2014-01-28 19.53.48.jpg
The door template for final routing.

[Sublimeballs]

Originally Posted by LarryS

Yes that's in the ballpark, we usually buy ten sheets at a time. Prices vary from time to time also. A single 4 x 8 x 1/2" sheet of black PVCX should run in the $85 range. I think the white is 5 to 10 dollars less per sheet.

If tools are an issue, many plastics suppliers will cut the sheets to size for a reasonable fee. You can build a cage using butt joints and screws with sliding glass doors for a very reasonable price.

Edit - oops Matt and I must have been typing at the same time.

Where can I find a supplier? Are you getting these locally or shipped? I really want to give it a go.

[LarryS]

Originally Posted by Sublimeballs

Where can I find a supplier? Are you getting these locally or shipped? I really want to give it a go.

Not sure where you are located. Here is our supplier.

Farco Plastics Supply Inc. - Locations

So far we have made the trip and picked up the material ourselves but the shipping rates are very reasonable. I think they were quoting about $50 to deliver 10 sheets. I'm about two hours from their location.

Make sure you post a build thread!