EASY step-by-steps TO MAKE A PHONE SPEAKER
Bottom 210 x 145 x 7mm Sides 95 x 210 x 7mm Top 195 x 145 x 7mm Phone blocks 45 x 13 x 7mm Stand 105 x 37 x 7mm Back 105 x 65 x 7mm Material Plywood Plywood Plywood Plywood Plywood Plywood Qty 1
Gather your supplies
900 x 600 x 7mm BC plywood
You’ll also need
Circular saw; pencil; jigsaw; fine sandpaper; sanding block; hammer; 15mm nails; long-nosed pliers; clamps; PVA glue; rag; nail punch, pine wood putty; clear varnish; paintbrush
STEP 1 Use circular saw to cut plywood pieces to the same length and slightly wider than the bottom, top and sides. STEP 2 Draw shape of bottom on the plywood. The front is 145mm wide and the back is 105mm. Make the middle of these edges on centreline of the ply. To set out the curves, draw lines from the corners at front and back and find their centres. Mark 10mm inside these points, then draw even curves from here towards each corner. The front
is also slightly curved from its centre to each side. Cut out shape with a jigsaw, retaining offcuts of the curves.
STEP 3 Draw shape of 1 side on ply. The front is 95mm wide and the back is 50mm. Make the middle of these edges on centreline of the ply. Use offcut of curve from bottom to draw curves on side. Cut out shape using jigsaw.
STEP 4 Use bottom as a template to draw top, making it shorter at the back for the phone slot. Also, use 1 side as a template to draw a second side. Cut out both shapes using the jigsaw, then sand all components to make smooth.
STEP 5 Mark thickness of ply on side edges of bottom. Halfway between this line and the edge, tap in nails, using pliers to hold in place.
STEP 6 To curve components, clamp offcuts to the sides and bottom.
STEP 7 With the sides upright, spread PVA along the top edges. Put bottom on these edges and drive nails home. Remove excess glue with a damp rag.
STEP 8 Repeat Step 5 to put nails along edges of top, then glue and nail to sides. Ensure front corners are flush to leave a gap at the rear.
STEP 9 Use nail punch to push the nails just below the surface of the plywood.
STEP 10 Fill nail holes using putty. Let dry then sand smooth.
STEP 11 Glue phone blocks to inside of bottom, flush with the back edge. Check that a phone can be supported.
STEP 12 Cut stand to size with curves on each end. Spread glue on top edge and clamp to bottom 10mm from the front edge. Leave to dry.
STEP 13 Apply 3 coats of varnish to exterior and interior of unit, and the back, sanding lightly in between. Allow to dry.
STEP 14 Glue and nail back to unit. Punch nails and fill holes. Allow to dry, then sand. Touch up varnish.