RBD, really the cut is not as hard as it looks. Truthfully, I never thought it could be done, but I haven’t messed one up yet. I tried a miter box one time and ruined two bodies before I went this way.
I’ll take your word on that. You have a good eye, better than most and it shows.
When is this “Buildoff thingamajigger” ?
I agree. Not only the vertical angle, but the blade will lay over slightly too. I always need to leave lots of space in a cut, about a minimags.
That looks great, good idea!
I’m excited to see progress. 
Nice work so far, Justin. Looking forward to your progress. 
Look in the new contest forum and see for yourself…
I had a teaser thread up on it since the first of the month. The sign-up starts the first of March and the contest starts in April.
Even using a good name brand chop saw that miter is difficult to do properly. Nice work, daunting work, glad you’re doing it and not me.
Updated the OP with a couple more photos.
Good question on how to do the screws up. Drilling holes in the side I suppose is out of the question. My first problem would be how to get the holes in the right position so the two halves stay aligned in all positions. My first thought is (dont know how to make it work) is the plastic plug type clips they hold dashboards and grills in these days so that the two halves press together. I no doubt know you will come up with some sort of black magic. Looking really good.
As with the contest it’s always fun to see how others overcome difficulties.
Interesting thread, looks like it’s coming together nicely. Look forward to seeing it finished.
Detents for a position and a stop? Gotta keep from twisting the wire too much too right? A detent or two for position points and a stop at straight and 90º so it stays within that short pivoting range will keep the wire intact. Hopefully. Otherwise, it’d take a continuous positive/ground rotating connection between the 2 plates.
A nylon locking nut will keep the screw from loosening or tightening up.
I might have a solution for your screw dilemma…… Solder or glue the nut fast so all you have is the screw to deal with and that should be no problem seein its a Philips.
Amazing work, seriously amazing.
Good choice with the TIR optics too.
I just used JB Weld on both ends of the screw. Filled up the ends, leaving just the wire hole. It ought to hold fine. Takes about 24-48 hours before I will do anything else with it. Besides another cold front is coming in and I can't do anything at work any more, so it will wait till it warms up again.
Not sure about the latest update but is this quits? Or is the JB Weld solution the latest status?
Sorry to hear it didn’t work out. I have to say though, your “fails” are far better than my successes!
Scribe a line and drill the screw hole first. Equidistant from that hole and on the line make 2 marks. After you connect the two sheets but before you solder them to the angle tubes hit the marks with a center punch. Rotate 180 and the punches line up again. Solder to tubes exactly in the right place. Easy to say, hard to get right. Other problems ensue, light goes to dumpster.