Does anyone have a suggestion on building vs. purchasing an acrylic case for their ship model? A well built model with rigging does not fair well when pitted against a curious cat, so protection is required. I’ve watched a dozen videos on how it’s done, but I have many doubts on how my unprofessional results will fair. Acrylic sheets can be cut on a table saw (I don’t have one), or scored and snapped on a line (creating rough edges) which might not glue so well or look decent.
I’ll take as many suggestions or comments as people will offer!
I have built about 20 ship cases for my models -- each for about $125. And we're not talking small cases -- some of these are three feet long (see pics). And the only tool I use need is a small hand miter saw. Here's how I do it:
Go to Home Depot, Lowes or a lumber yard and buy a 3/4" or 1" thick pine board at the appropriate width (i.e. 6" - 10"). I like pine because it's cheap and takes stain really well, but you can spend more money and buy other wood if you want. Have it cut to your desired length (most places will cut it for you for free). Cost: About $17.00.
At the same time, buy strips of decorative or plain molding. Make sure the molding is taller than your board. For example, if you board in 3/4" thick, get a 1" tall strip of molding. Most of them come in 6' sizes. These you can cut at home. Cost: About $20.
For the inside "track" for the acrylic and the display case frame, buy 1/4" strips of wood. These come in various lengths, usually 4'. Cost: $15.
Cut the molding strip to fit your wood base. For a professional look, use a 45" diagonal cut.
Glue the molding to your base; it should rise 1/4" above the base. Sink penny nails into the sides for stability and fill the nail holes with wood filler.
Make a "track" for your acrylic sides by cutting and gluing 1/4" strips of wood 1/4" away from the outside molding. Now you'll have a 1/4" wide and deep track all around the base -- no mitering or sawing necessary.
Stain the assembled base and the wood strips you'll be using for the frame. Be sure to use pre-stain because otherwise it will be splotchy. Also, many of the decorative strips have epoxy in them, which doesn't take stain well. If you use a water-based stain, no problem but oil-based stains might be problematic. You can also paint the wood and/or molding if you wish.
Polyurethane the assembled base and the wood strips to your taste: flat, satin or glossy. Do the usual routine -- multiple coats followed by light sanding.
Now for the acrylic. I use 1/4" acrylic sheets for my cases. I find it is not too thick and not too thin, especially for large cases. I have found that Professional Plastics, Inc., which has offices around the country, does an excellent job of cutting acrylic to my exact dimensions. They charge by the cut, so typically it costs $125 for five pieces: front, back, sides and top. Your acrylic should precisely match the measurements of your "track". Don't forget to measure the top properly. And choose whatever height you want.
I use resin to glue the acrylic. Nothing else seems to work. "JB Weld" works great and comes in those nifty double-barrel "guns" for mixing. Make sure you do it in a well-ventilated place.
I assemble the acrylic this way: I glue the edge of one side and insert it and the back of the top into the "track" on the base. Take care not to glue the bottom 1/4" of the pieces lest they stick to the base. Also, do not move the side piece once it's in place because the resin gets messy. Clamp for 30 minutes. Next, glue the other side to the back and clamp for 30 minutes. Finally, glue the front on, and clamp. Leave overnight. To add the top, I wedge a piece of wood between the front and back of the case, precisely matching the correct width. This prevents the front and back from "bowing" while you put on the top. Once that's done, apply your resin to the top of the walls and carefully lower the top onto it. Once it's in place, put some books or other heavy objects on it and let sit for a day.
In most cases, I've found these acrylic tops are strong enough on their own. However, for esthetic reasons and extra strength, I put a frame around both the outside and inside of the cases. This makes them super strong and very attractive. To do so, I use 1/2" corner moldings, which I get at the aforementioned stores. I stain and finish them to match the base and cut to size using my trusty saw and miter. Staring with the top, I use resin to affix the molding to the top and sides where the two acrylic pieces meet (this also hides the glue and any mistakes made in applying it). I clamp the sides and put books on top of it for a tight fit. For the legs, I cut the same corner moldings to size -- fitting them so they precisely touch the base. I use the resin and clamp. I let the whole thing sit overnight to set.
The next day, I remove the case from the base and turn it over. I then take my 1/4" strips of wood and using resin again, glue them to the acrylic seams on the top and sides. This further reinforces the case and adds to the professional look.
Finally, I use an acrylic cleaner (not glass cleaners), to polish to acrylic and it's done!
Total cost: Under $200
Total time: Three days
No professional tools necessary