posted 12/9/07
On Wednesday, December 5th, the trio of WB8NSL, W8TVC and WA8ZWJ got together for another Flat KBob making session. This time, we were working to make a new stand up Flat KBob. In the top left panel below you see that we have made the preliminary layout of the print on the masonite. In the top right below we have glued the two pieces of the print together. Then we traced the outline with carbon paper underneath. In the middle left below we are touching up the carbon paper traces to make it easier to follow with the saber saw. In the remainder of the photos in the panel we are cutting out the form.
Below top left we are trimming off the rough edges after the cutting has been done. In the mean time, Flat KBob rests on the couch. In the bottom photo of this panel the new Flat KBob masonite form stands among us for the first time.
On Saturday, December 8th the trio reassembled to complete the project. Top left below you see Charlie putting the final touches on the support framework that will be the backbone of the new form. No comments can be made that this Flat KBob is spineless! We used a series of flat head wood screws to mount the frame to the form. This entails a process of drilling the holes and then counter sinking the masonite so the screw heads are flush on the front (see top right and both middle photos). Then the screws were removed and glue was applied to the framework and the screws reinserted - so the new Flat KBob has been glued and screwed (see bottom two photos).
Below top left you see the masonite form and framework glued and screwed together laying flat face down on the floor while the glue has a chance to dry. The top right panel below shows the final part of the most tricky portion of the process - the gluing of the print onto the masonite. For this we used a special spray adhesive made for wood and paper. The reason there are not more photos of this portion of the process is because we were all too busy to take pictures. This photo shows W8TVC and WA8ZWJ smoothing the print and eliminating any air bubbles or bulges between the print and masonite. The bottom two photos show the trimming of the printed form on the masonite using razor knives.
In the shot below you see left to right: The Original Flat KBob (which was first introduced to the IOOK at the 2005 HamVention Gathering Of The Faithful), W8TVC, New Flat KBob, WB8NSL, The New Sit Down Version Of Flat KBob, WA8ZWJ
The only thing remaining to be done to finish the project is adding a hinge and support prop. A special "Thank You" to Mike, N7LMJ, for getting the prints made. Also, thanks to Dave, W8TVC and Charlie, WB8NSL for their assistance!
Respectfully submitted, Keith, WA8ZWJ, Vice President, IOOK
