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Old 30th December 2013, 01:25 PM   #1
kuroguy is offline kuroguy  United States
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Default LM4780 Mini amp - Completely DIY

I started by designing and machining the front panel. It is made from 2" wide 6061-t6 bar stock. Width is 10". machining required 3 steps. letters are carved with a 60 degree V bit. small holes are cut using a 1/16" end mill and larger holes are cut with a 1/8" end mill. The panel is machined on my DIY CNC router table. I'd never used it to machine aluminum until yesterday. it does a pretty good job.

After milling, I polished it with jeweler's rouge and a buffing wheel on my drill press. total time to make this panel was about 90 minutes.

next I'll work on the rear panel.
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Old 30th December 2013, 07:31 PM   #2
troystg is offline troystg  United States
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Nice work so far..

Is it the camera angle or is that really oval LED's?
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Old 31st December 2013, 01:51 AM   #3
kuroguy is offline kuroguy  United States
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The LEDs are oval. I didn't realize they were elliptical until they arrived. The great thing about having a CNC router is that it was a pieceof cake to cut the elliptical holes for them.

Worked on the input section and power led circuitry tonight. Tomorrow i'll cut the rear panel and will be able to start putti g the guts of this amp together.
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Old 31st December 2013, 05:00 PM   #4
kuroguy is offline kuroguy  United States
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This morning I worked on the back panel. First I clamped a piece of scrap wood in the CNC and milled a pocket for the 2" bar stock to sit in. This allows me to accurately place the bar stock with respect to the CNC's coordinate system as well as ensures the bar sits parallell to the XY plane of the machine (in case it isn't perfectly flat. Any skewing of the bar will result in the lettering being cut poorly since it isV carved.

Next I cut all of the holes using a 1/16" end mill followed by cutting the lettering using a 60 degree v bit.

After that i polished it and mounted all the hardware that connects to the panel. Total time today: 3 hours.

Next is to cut the wood sides and bottom and aluminum top.
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Old 31st December 2013, 05:09 PM   #5
troystg is offline troystg  United States
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Curiously watching... :-)
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Old 31st December 2013, 05:25 PM   #6
kuroguy is offline kuroguy  United States
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Pictures....
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Old 31st December 2013, 05:32 PM   #7
SoIL4x4 is offline SoIL4x4  United States
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Great build! I really like the lettering. Do you have any pics of your cnc setup? Or some more info on it. I have been considering going this route for various other projects, and am curious what others are using to get results like this.

Pics...pics..pics

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Old 31st December 2013, 05:34 PM   #8
kuroguy is offline kuroguy  United States
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Having problems uploading....
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Old 31st December 2013, 05:36 PM   #9
kuroguy is offline kuroguy  United States
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Another...
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Old 31st December 2013, 05:37 PM   #10
kuroguy is offline kuroguy  United States
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And another...
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