Construction
The day I got word that my prototype and plans got the green light, I was at the hardware store comprising a massive order. 40 sheets of black melamine, which clear out stock in 3 of the surrounding cities near me, 50 nickle plated hinges, cam locks, furniture braces, and countless screws, melamine tape and melamine glue.
I started with cutting everything down to size using my table saw. I needed to include a sturdy shelf (for the console to sit on top of) so I adjusted my table saw to cut 5/8 inch Dado's so the shelf can slide in and be glued/screwed into place - this provided with a clean interior with minimal brackets.
After cutting the melamine material down, I started assembly with special melamine glue and particle board screws. The combination of these two made sure that the boards will not come apart. The hinges were installed and the door with a cam lock + key were installed. After the 4 sides of the cabinet and shelf were put together, the top was glued and screwed into place. After the glue set, I used a heat sensitive melamine tape to cover all of the exposed particle board. The last step was to drill holes into the back, corner of the cabinet and top to allow cables to be run inside the interior and provide a clean, sleek look.
Rinse and repeat 25 times.
The next morning, they were finally done and were ready for pickup. I had these set up all over my garage and living room. We loaded them into a over sized moving truck and sent them away. The next time I would see them would be at the actual show - Toronto Fan Expo at the Xbox One booth all hooked up with Xbox One consoles and massive curved screen TV's showcasing the newest and greatest video games Gears of War 4, Forza Horizon 2 and in the VIP booth.
