A block; this is white beech, cut to size - exactly scaled from a standard international 20ft shipping container.

The first step was to remove the corners in order to let in the aquare section brass rod. This was done by building a simple router router table and running each one through. After a few where the beech would split when the router got to the end of the cut, I developed the technique of cutting the last part first, avoiding splitting it by offering the block into the center of the cutter; rather than the edge.

The next challenge was how to make a nice opening in the bottom of the blocks to take the electronics. For this I built a simple jig that the blocks would slide into, and then be clamped in the bench. Then the opening at the top would provide a guide for the router. Shown here are 2 views of the mk1 jig. mk2 had a more accurately cut top section.

Detail of a cut block; as you can see it is not totally satisfactory - hence the Mk2 Jig. Even this however was not as accurate as I would have liked … a problem to be solved aanother time!

A block with the routing completed.

30 completed blocks!

Next time - the metal work