Banana PC jr. 6000 - Alpha Build

DJPinter

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Ok...let's try this again. Pardon th etpying. I had to get 4 stitches in my left index finger today. I didn't cut it on the model. I was opening a baking soda box for our cat's litter box with my pocket knife.

First some metrics.
There are 202 parts. At least they aren't small parts.
Screen Shot 2018-06-17 at 5.26.20 PM.png

Banana Legs & Feet.pdf
Banana Legs & Feet.png

Banana Pants & Shoes.pdf
Banana Pants & Shoes.png

Bulkhead.pdf
Bulkhead.png

Exterior - Apple/Banana/Veidt.pdf
Exterior.png

Interior.pdf
Interior.png

Light Kit.pdf

Light Kit.png
 
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DJPinter

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Bulkhead
Since I don't have a printer that can handle 1/8" corrugated cardboard I printed the Bulkhead parts out on 8.5” x 11” (216 mm x 279 mm), 67 lbs. (147 g/m2) paper, then spray glued the printouts to copier paper boxes. Because of the part size I was only able to get two big parts per box, one on the box bottom and another on the box lid.
IMG_0346.jpg

There are two variations in Bulkhead.pdf. Part B.4.7-B & V are for the Banana and Veidt variants. B.4.7-A is for the Macintosh. The Mac part had an interruption of the inside of the original Mac 128k. All the people that worked on the project got their signatures engraved on the inside of the case back.
IMG_0349.jpg IMG_0348.jpg

I'm building the Banana PC jr., so B.4.7-B & V will be used.
 
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zathros

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Laminating is the norm on thick parts. This is an awesome model!! :)
 

DJPinter

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Case Back - Bottom Panel
Bulkhead.pdf
B.4.6​
Exterior - Apple/Banana/Veidt.pdf
B.0.8​
1 3.jpg
Laminate B.0.8 to B.4.6. Attach rubber feet.
IMG_0193.jpg IMG_0196.jpg
2.jpg
Laminate B.0.8 to B.4.6. Cut out the Xes. These are where the Banana legs will attach.
IMG_0194.jpg IMG_0353.jpg IMG_0355.jpg IMG_0354.jpg
 
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DJPinter

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Case Back - Side Panels
Bulkhead.pdf
B.4.1
B.4.2
B.4.4
B.4.5​
Exterior - Apple/Banana/Veidt.pdf
B.2.3
B.2.4
B.0.10
B.0.9​
Interior.pdf
B.3.4
B.3.5
B.1.10
B.1.11​

Left Interior
Laminate B.4.1, B.3.4 and B.2.4 together aligning the leading edges and vents as alignment guides.
IMG_0362.jpg

Notice that B.3.4 and B.2.4 overlap B.4.1 by 3/16" (4.75 mm).
IMG_0369.jpg

Final piece.
IMG_0365.jpg

Right Interior
Laminate B.4.4, B.3.5 and B.2.3
IMG_0363.jpg

Left and right parts.
IMG_0366.jpg

Left Exterior
B.4.2, B.1.10 and B.0.9. Laminate B.1.10 and B.0.9.
IMG_0367.jpg

Glue the Left Interior part to B.1.10/B.0.9 using the vents and bottom edge as alignment points.
IMG_0370.jpg

Glue B.4.2 onto B.1.10/B.0.9. Make sure B.4.2 is up against the Left Interior part. Notice that there is a 3/16"(4.75 mm) overlap on top of B.4.2.
IMG_0371.jpg IMG_0372.jpg

Right Exterior
B.4.5, B.1.11 and B.0.10. Assemble the Right Exterior part in the same manner as the Left Exterior part.
IMG_0368.jpg

Both back case side walls assembled.
IMG_0373.jpg IMG_0374.jpg
 
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DJPinter

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Case Back - Back Panel
Bulkhead.pdf
B.4.7-B & V/A​
Exterior - Apple/Banana/Veidt.pdf
B.0.1
B.0.11
B.0.13
B.0.14
B.1.2
B.1.3
B.3.1
B.3.2​
Interior.pdf
B.1.1
B.2.1​
Light Kit.pdf
LK.8-A/B/V
LK.9-A/B/V
LK.10-A/B/V​

Trace B.3.1 over the back of B.4.7-B & V/A. Cut the first layer of material off of the corrugated cardboard. Leave the corrugated material intact.
IMG_0375.jpgIMG_0377.jpg

Glue B.3.1 on top of the corrugated material. Then laminate B.2.1 on top of B.3.1. Next laminate B.1.1 onto the panel. Finally, laminate B.0.1.
IMG_0378.jpg IMG_0379.jpg

Note the 3/16" (4.7 mm) overhang on the left, right and bottom of the part.
IMG_0380.jpg

Attach the logo badge (B.0.11), name badge (B.0.12) and regulatory plate (B.0.13) as shown.
IMG_0381.jpg IMG_0382.jpg

Fold the Kensington Lock Slot (B.1.2) and Accessories Box (B.1.3) with the printed edge inward.
IMG_0384.jpg

Attach the Kensington Lock slot and Accessories Box to the panel.
IMG_0397.jpg

Fold the Power Box (B.3.2) with the printed side inward.
IMG_0385.jpg
Off.jpg

Glue the Power Box to the panel. You're done if you don't plan on using the Light Kit.
IMG_0386.jpg
On.jpg

Laminate the Battery Box Bracket (LK.9-A/B/V) on top of the Power Box. Cut out the three rectangles. Attach the Power Box as shown.
IMG_0388.jpg IMG_0389.jpg

Cut off 1 cm of one of the top Battery Box (LK.8-A/B/V) flaps. Fold the Battery Box with the printed side inward. Attach to the back of the Power Box.
IMG_0387.jpg IMG_0390.jpg

...to be continued...
 
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DJPinter

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Case Back - Back Panel: Part II
Fold the Battery Box Door (LK.10-A/B/V) as shown.
IMG_0391.jpg IMG_0392.jpg IMG_0393.jpg IMG_0394.jpg

Insert the wide bottom Battery Box Door tab into the wide slot on the Battery Box Bracket.
IMG_0395.jpg

Insert the narrow top Battery Box Door tab into the narrow slot on the Battery Box Bracket. Well, try to at least.
IMG_0396.jpg
 
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zathros

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Really excellent design and your build is awesome. Let me also compliment you on an excellent design/build thread. :)
 

DJPinter

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I found that cutting all the vent slots was tedious so I started laminating parts with slots before cutting the slots (because I have a double wall construction). It worked well. Unfortunately, the top panel is the last part where I can do this. Fortunately, laminating parts will eliminate some interior parts. Unfortunately, that means going back to the Rhino and Pepakura and rearranging stuff. I'll keep pressing on and do that modification for the beta files.

Case Back - Top Panel
Bulkhead.pdf
B.4.3​
Exterior - Apple/Banana/Veidt.pdf
B.0.2
B.0.3
B.0.4a
B.0.4b
B.0.5c
B.0.5
B.2.2​
Interior.pdf
B.3.3​

Laminate a piece of cardstock on the back of B.0.2, B.0.3 and B.0.5. Cut out all the vent slots on B.0.3 and B.0.5. There's 44 on each piece and they are 2mm across with 2mm between each slot. After your hand cramps go away cut out B.0.2.
IMG_0407.jpgIMG_0408.jpg

Get more hand cramps by cutting out the slots on B.2.2 I got tired of cutting out vent slots so I removed them from B.3.3.
IMG_0415.jpg

Laminate B.3.3 to B.4.3 using the back edges for alignment. Laminate B.2.2 on top of B.3.3. Fold the flap on B.2.2 over the edge of B.4.3.
B.2.2.png
IMG_0416.jpg

Cut two .25" strips off a sheet of copier paper. Glue them to the back of B.0.2 as shown.
IMG_0418.jpg

This is where you will glue the handle recess to. After the glue has dried laminate B.0.2 on to B.2.2. The top panel should look like this at this stage.
IMG_0422.jpg

CAREFULLY attach B.0.3 and B.0.5. You should see a 1mm section of B.2.2 though the slots in B.0.3 and B.0.5. There should be a hairline gap between B.0.3/B.0.5 and B.0.2.
IMG_0424-2.pngIMG_0423.jpgIMG_0437.jpg

Cut out B.0.4a, B.0.4b and B.0.4c. Score the valley folds on B.0.4b as shown. Use two 0.25" strips of copier paper and attach B.0.4a and B.0.4c to B.0.4b.
IMG_0421.jpg IMG_0425.jpg

Roll B.0.4a and B.0.4c to follow the contours on B.0.4b's middle section. Roll the top of B.0.4a and B.0.4c so that the combined parts look like this.
B.0.4.jpg
IMG_0426.jpg

Slide B.0.4a-c into the top panel recess with the slots on B.0.4a and B.0.4c going over B.4.3/B.3.3/B.2.2. Use strips of copier paper to attach the part.
IMG_0431.jpg IMG_0432.jpg IMG_0428.jpg
 
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DJPinter

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Interlude
While I'm looking for something to use as a jig, here's a preview of the case back assembly. The side panels are perpendicular to the bottom and back panels. The top and bottom panels are the same width. Therefore, if you remember your high school geometry, this means that the top panel is perpendicular to the side panels, too.

The back panel's bulkhead (B.4.7 B & V/A) rests on the bottom panel's bulkhead (B.4.6) and is between the side panels' bulkheads (B.4.1, B.4.2, B.4.4 and B.4.5). The back panel's exterior (B.0.1) should be inside of the side panels and the bottom panel's exterior is inside the back panel. This will expose the side panel's edge to the back of the model and the back panel's bottom edge to the bottom. You might have to trim the back panel's exterior to achieve this.
Screen Shot 2018-07-22 at 1.37.46 PM.png

The side panels' bulkheads parts (B.4.1 and B.4.4) rest on top of the bottom panel's bulkhead (B.4.6). The bottom panel's exterior (B.0.8) should be inside of the side panels. This will expose the side panel's edge to the bottom of the model. You might have to trim the bottom panel's exterior to achieve this.
Screen Shot 2018-07-22 at 12.39.42 PM.png

The side panels' bulkhead parts (B.4.1 and B.4.4) fit into the notches in the top panel's bulkhead (B.4.3.). The remainder of B.4.3 rests on B.4.2 and B.4.5. The top panel's exterior (B.0.2) should be inside of the side panel. This will expose the side panel's edge to the top of the model. You might have to trim the top panel's exterior to achieve this.
Screen Shot 2018-07-22 at 12.55.29 PM.png Screen Shot 2018-07-22 at 12.04.31 PM.png

There is a 0.6" (16mm) lip on the side and top panels. This lip will be inserted into the case front. You may have to trim the lip on some of the panels to have a consistent width.
Screen Shot 2018-07-22 at 1.14.19 PM.png

To summarize: the angles are all 90 degrees, the top and bottom panels fit inside the side panels, and the lip around the side and top panels is 0.6" (16mm) wide.
 
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