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ISAC Build - Size the Wood
Monday, October 3, 2016
By Wulf

First of all, I do not have pictures for the entire build, I apologize. Where I do not have actual pics, I will provide reference images instead.

Take your scrap 2x4 and cut a piece a little over 4 1/2'' long and about 2 3/4''s wide. Decide which side is going to be the top and the bottom. Working on the bottom, plane the wood down to 1'' high (yes, take off 1/2'').

ISAC Build - Creating Light Housing Space
Monday, October 3, 2016
By Wulf

Once you have your board, you need to figure out where you are going to put the light. I picked a side to have the light and marked two lines, one at 7/8'' and the other at 2 3/8'' (roughly, I am horrible at reading rulers).

After marking the lines, triangulate the exact center of the board and mark it as well.


Drill a pilot hole all the way through the wood where x marks the spot. Take your 1 1/8'' spade bit and drill a hole. Go low and very slow (high torque low speed) with the spade bit as it will catch the wood and, if you forget to set your drill to stop spinning when it gets stuck, you can give yourself a black eye (true story).

You want to drill down roughly 3/4'' but all that depends on the housing for your light beacon, which I will discuss later. You do this with two spade bits to create a shelf for your light to sit on so do not drive all the way down.

NOTE: You want to have the light housing already assembled before you plasti dip the ISAC in case you need to make changes - you want the top of the housing flush with the wood so plan accordingly. Also, the plasti dip will take away a little of the depth of the hole, not much but it depends on how thick you have applied it.

Once down, switch to the 1 1/2'' spade bit and redrill the hole. Low and slow, or you will shred your wood. Do not go down as far as you did the first time. Once finished, recharge your battery on your drill (oh, wait that might have just been mine), but seriously the spade bit will drain your battery.

You can, if you want, drill the larger hole first and then the smaller hole - it depends on what you think will work better.

Grab your sanding materials and get to work on the edges of the hole - the hole itself will be filled so sand it if you want to (I didn't). You want to smooth out anywhere the wood split from the spade bit.