Alien - Area 51 RGB Headphone Stand
Introduction: Alien - Area 51 RGB Headphone Stand
This Instructables I guess I have been writing for the third time and the different thing is that every time I build this the process is entirely different and it's like the level of difficulty kept on increasing. So the first time I made it with simple hand tools, the second made with CNC but since I was new to that I didn't play much with that and the design kept quite simple. But now at the end of 2020, I made it so well that I don't think I am really gonna made one. The one downside is that it tremendously increases the working time. There are so many small details and areas where I have to machined first and then fill the resin and then machined again to remove the material so that I am able to install the led into the stand. There are some areas where the resin gets leaked out because of a very tiny hole and the next day when I came to see the result it's a complete disaster. I personally think that no matter how perfect you are these tiny mistakes definitely going to happen. There might be a chance that my work of approach is wrong but these things happen. I build two stands and the build time is 72 days. Yes, it looks insane time for these tinny little things but it happens. The design work took around 11 days because I need some inspiration and so many things needed to be designed in such a way that I am able to machine them easily with my 3 in 1 CNC and frankly say that is definitely a big test for that CNC as well. I can proudly say that machine works like a charm. Few minor flaws like tiny dust particles seen in the casting at 2-3 places I can say that this thing is definitely executed well from my perspective, rest I leave it up to you guys, that what you think about this build. The only change I wanted to do in this build for the next time is to use stabilized wood, but without any doubt that thing tremendously gonna increase the cost. I guess a normal person who never stepped into this manufacturing line he didn't know much about the complexity of this build but my maker friends will definitely know how tough this thing is. 215
Again I thank you to give your valuable time to my Instructables.
Supplies
Material and parts used
Following are the list of material used in this build
● African wenge wood
● Two part slow set epoxy(low viscosity)
● ESP8266
● WS2812 led strip
● Power connector 2.1mm
● 5v 10amp power supply.
● Allen bolt 4mm
● Allen bolt 8mm for the neck 70mm long with nut.
● Wire
● Glue gun
Step 1: ​Material Cutting.
The wood I have comes in wide planks of 12" wide and 11⁄4" thick so I designed the layout in such a way that I am able to cut out one set at a time with my CNC. Luckily the size is under my machine limit so there wasn't much of a problem. So the initial size I cut onto the chop saw but the wood is so damn hard that the blade actually starts to smoke and struggle a lot. The entire room was full of smoke. With the required size, I make two cuts and then move onto my CNC for the flattening and contour operation. Here one thing you need to understand is that wenge cause problems to the health like sneezing, coughing and breathing issue and it kept on leaving colors to your hand which took time to fade away. So definitely consider these things in mind while working with wenge wood.
Step 2: ​Surface Roughing and Contour Path.
Since I didn't have many woodworking tools that's why I completely depend upon my CNC. But I think if you are able to acquire those planners and sander or at least know people who do this work definitely completed this task over those machines. It's surely gonna saves you a lot of time. The first thing I did is to put the machine onto the bed and then start the clamping process. The main goal is to prevent any wood movement due to the force of the tools during machining. On the three sides, I used stop blocks but onto one side, I use a wedge system for clamping. One thing I also measured is the thickness of the board even though it's 11⁄4" but due to light warpage and shrinkage it's uneven from different sides. Once I secure it completely with the help of 1" flat bit I started the roughing work. Once the one side has been completed I just flip it over and did the same on the opposite side. Once both the process has been completed I start the work onto the contouring process in which I have to remove the Alien head and the bottom triangle.
For the main contour of the putter periphery I use 6mm bit. 582