Wednesday, October 28, 2009
Ground board made.
I also drilled a 1/2-inch hole in the center of the rocker box bottom, then applied contact cement to it and the Formica that will slide over the Teflon pads. After the cement became tacky, I pressed the laminate into place with a roller then removed the excess using a rotary tool and a laminate trimming bit. Then I primed the inside of the rocker box with Kilz primer and followed that with two coats of flat black paint. On the outside, I did a final sanding and followed that with the first coat of exterior grade glossy polyurethane.
To secure the ground board and rocker box together, I will use a 1/2-inch stainless steel hex bolt and two three by three-inch steel plates I made from flat stock. In the center of each, I drilled a 1/2-inch hole. At each corner I drilled a hole for a #8 screw. To one I welded an all-metal lock nut. When the bolt is screwed into the nut, it will not rotate and confuse the digital setting circles that will be added later. The other metal plate was screwed to the bottom of the rocker box and will act as a fender washer and bearing for the bolt to prevent wandering. After cutting, drilling and welding, they were primed and painted flat black.