Despite being a self-proclaimed CNC novice, Sebastian embarked on a challenging project to acquaint himself with his new CNC router – crafting a wooden replica of an original Game Boy case. Remarkably, he succeeded in creating a faithful reproduction. Walnut was selected as the material, offering an excellent choice for woodworking, although it can be demanding and tool-sensitive. To tackle the task, Sebastian employed nine different tools to achieve precision.
One of the project’s complexities involved reproducing the intricate details of the original injection-molded plastic Game Boy case. This entailed creating both top and bottom shells, each milled from both sides, which presented registration challenges. The solution was specific indexing holes and the “blue tape and CA glue” technique for fixturing. Additionally, the front face’s lettering was expertly milled using an engraving bit, filled with white spray paint, and polished with a surfacing bit, resulting in striking labels against the dark wood.
However, Sebastian faced some limitations due to wood’s differences from plastic, such as the inability to hold screw threads in small studs without splitting. Consequently, the case had to be glued shut once a mix of salvaged and new components were integrated. Nonetheless, the final result was a single, unique piece of art, showcasing Sebastian’s impressive woodworking and CNC skills.