Ikea CR10 Enclosure Instructions
Doors
The doors are pinned together with 50-60mm x 5mm steel dowel pins. I used Gorilla Super Glue Gel and Gorilla Glue Clear as the adhesives to hold the doors together. The 1/8" Lexan (Plexiglass) sheet used is approximately 457x665mm for the left side door (the right side door will be shorter). Once all the parts are printed, the latch mechanism can be assembled first. I will update the latch instructions later
The first step is to install the frame parts, which will allow the door to be hung. These are shown in the pic below. The cyan color parts are the hinge parts, which have a bronze bushing installed (5mm bore, 9mm OD 10mm length). I also placed an M5 washer over the bearing and glued that in with superglue. The orange color parts are actually 2 parts which need to be assembled using M3 hardware (more details on this part will be added later). The green color parts are just spacers. At the top there are 3 parts (light blue) which create a top frame for the door. This top frame can be glued prior to installation and will require some #8 screws which will help secure it to the top of the enclosure. Along the right side of the frame, there are 3 parts. There are 2 spacers in pink (they are not the same size), and in the center in purple is the strike plate for the door latch. All the frame parts are secured to the 4545 extrusions using M5 x 16mm button head screws and M5 T-nuts for 4545 extrusions.
The first step is to install the frame parts, which will allow the door to be hung. These are shown in the pic below. The cyan color parts are the hinge parts, which have a bronze bushing installed (5mm bore, 9mm OD 10mm length). I also placed an M5 washer over the bearing and glued that in with superglue. The orange color parts are actually 2 parts which need to be assembled using M3 hardware (more details on this part will be added later). The green color parts are just spacers. At the top there are 3 parts (light blue) which create a top frame for the door. This top frame can be glued prior to installation and will require some #8 screws which will help secure it to the top of the enclosure. Along the right side of the frame, there are 3 parts. There are 2 spacers in pink (they are not the same size), and in the center in purple is the strike plate for the door latch. All the frame parts are secured to the 4545 extrusions using M5 x 16mm button head screws and M5 T-nuts for 4545 extrusions.
Once the frame parts are assembled, the door can be assembled. After building one door, I will describe the best way I think it should be done.
I assembled the hinge side of the door using 50-60mm 5mm dowel pins, and super glue. First make sure any oils are removed from the dowel pins by cleaning with alcohol. Then Install 2 pins in one side of each part being assembled for the hinge side (there will be a top, middle and bottom). Allow the glue to dry on one side fully, before assembling the parts together. Once the pins are installed for one side of each part, I set up a clamp so that I could tighten the parts together quickly once the glue was laid down. I added some superglue to the mating surfaces and then placed the top, bottom and side parts in the clamp, which was tightened down, and then it was allowed to dry in this frame. The pics below are of the latch side which I glued up the same way.
I assembled the hinge side of the door using 50-60mm 5mm dowel pins, and super glue. First make sure any oils are removed from the dowel pins by cleaning with alcohol. Then Install 2 pins in one side of each part being assembled for the hinge side (there will be a top, middle and bottom). Allow the glue to dry on one side fully, before assembling the parts together. Once the pins are installed for one side of each part, I set up a clamp so that I could tighten the parts together quickly once the glue was laid down. I added some superglue to the mating surfaces and then placed the top, bottom and side parts in the clamp, which was tightened down, and then it was allowed to dry in this frame. The pics below are of the latch side which I glued up the same way.
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Once the hinge side of the door is assembled, it can be test fit in the door frame to verify there are no clearance issues. The Latch side of the door should not be assembled until the plexiglass/lexan is cut to size.
If it looks good, then the polycarbonate sheet needs to be cut out. First cut it to size (approximately 457x665mm for the left side door) - the right side door will be shorter. Once at the correct size, the template can be used to mark where to cut the pocket for the latch. See the pic below for how the template was used. I used some short 5mm dowel pins to help with the alignment of the template.
If it looks good, then the polycarbonate sheet needs to be cut out. First cut it to size (approximately 457x665mm for the left side door) - the right side door will be shorter. Once at the correct size, the template can be used to mark where to cut the pocket for the latch. See the pic below for how the template was used. I used some short 5mm dowel pins to help with the alignment of the template.
Once the pattern is traced onto the polycarbonate sheet, it can be cut out. I used a hacksaw, drill, and a plexiglass cutting tool which was only used for the part which I could not reach with the hacksaw. I used a drill to create the radius in the corners (sorry I missed the size, but it is a 10mm radius / 20mm diameter). This hole does not need to be perfect since there is a bit of overlap which will cover it.
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Now that the clear sheet is cut, the latch side of the door can be assembled in the same way as the hinge side was assembled. Prior to assembling the latch side though, I took the opportunity to test fit the door in the frame.
If it looks good, then the hinge side and latch side of the door can be assembled. I first installed the 50-60mm pins on one side only, these were glued in with superglue.
To bring the halves together I used only Clear Gorilla Glue, instead of the superglue, in order to get more working time. I peeled back the masking on the clear sheet, around the edges and added the glue in the grooves it will go into, being careful to not use too much that it would ooze out. I also added glue to the mating surfaces and pins between the hinge and latch side parts. The sides were then brought together and clamps were used at the top and bottom to bring the parts together. The door was allowed to dry completely before removing the clamps.
To bring the halves together I used only Clear Gorilla Glue, instead of the superglue, in order to get more working time. I peeled back the masking on the clear sheet, around the edges and added the glue in the grooves it will go into, being careful to not use too much that it would ooze out. I also added glue to the mating surfaces and pins between the hinge and latch side parts. The sides were then brought together and clamps were used at the top and bottom to bring the parts together. The door was allowed to dry completely before removing the clamps.
Once the door is glued up, the wedge shaped inserts need to be installed on the hinge side. These are glued in using superglue and the 60mm x 5mm steel dowel pins. The pins need to extend about 10mm below the hinges, to allow the door to be lifted off the hinge when it needs to be installed or removed.
Additionally, two covers need to be installed on the latch. The back cover is held with four M4 nuts and M4x16 to 20mm screws. There is also a small cover which covers the hole that was used to install the pin inside the latching mechanism. This is installed with an M3 insert and M3x10 to 16mm screw.
The door frame was designed to be sealed using the rubber weatherstripping linked here. The weather stripping will go around the left, top and right sides of the frame. It can also be added to the bottom of the door.
Additionally, two covers need to be installed on the latch. The back cover is held with four M4 nuts and M4x16 to 20mm screws. There is also a small cover which covers the hole that was used to install the pin inside the latching mechanism. This is installed with an M3 insert and M3x10 to 16mm screw.
The door frame was designed to be sealed using the rubber weatherstripping linked here. The weather stripping will go around the left, top and right sides of the frame. It can also be added to the bottom of the door.
