My first attempt to make a chassis

[S.C]

Originally posted by Nuuk

All I can suggest to give you the best possible chance of completing your case successfully is don't make it too small, in other words allow for something needing more room than it appears to; remember to allow for fixing components, ie how will you get a screwdriver or spanner to it; and probably most important, mock up the case using MDF or plywood first.

Hehe, I did the cardboard phototype. I think I need to try the wood phototype this time.

Originally posted by Magura

Besides that you should make sure you get electrlytically clean copper, anything else will most likely contain something the aluminium dosnt like and cause corrosion.
Magura

I think my uncle's work place will do the job. He is working in a electric paint something. They paint lke rims, aerodynamic stuffs.

Originally posted by elizard
I found it that most of these stores are quite expensive, including online metals.

The shop I got my aluminum from is called speedymetals
just as an illustration of the price, one 9"x3.5" 1/8" (6061-t651) plate cost me $3.78 ..
no minimum orders, no charges for cutting

sadly, no website, but if you email them at speedymtls AT aol DOT com they'll give you a quote (btw, i did the email like that so i don't cause them griefs w/ spam)

Um. Thx e-mail for the address. I will send a quote e-mail. I knew that online metal is quite expensive. That's why I said the materials is kinda expensive in the beginning.

Ohoh, I don't have many tools around, but my cuz used to work in some computer company that will deal with building chassis. He said he will bring me there to use the drill press... tools....

All the tools I have is few srew driver, a drill, and hammer..... If I have a table saw life will be much easier.

[elizard]

Originally posted by S.C
Ohoh, I don't have many tools around, but my cuz used to work in some computer company that will deal with building chassis. He said he will bring me there to use the drill press... tools....

All the tools I have is few srew driver, a drill, and hammer..... If I have a table saw life will be much easier.

speedy will cut them to size for free
i found that their cuts are pretty precise, so nothing to worry about it there

then all you need is a drill (drill press preferred) and a tap to make the threads (plus the basic tools of course, like a screwdriver, etc)

[S.C]

Originally posted by S.C

Dimensons: Thickness X Width X Height ("=inch)
Aluminum 6061-T6 Bare Plate 1 (Left/Right)
0.375" x 8" x 7"
Aluminum 6061-T6 Bare Plate 2 (Front/ Back)
0.375" x 4" x 7"
Aluminum 6061-T6 Bare Plate 3 (Top/bottom)
0.375" x 4" x 9"
Aluminum 6061-T6 Bare Extruded Square
0.75" x 3"
Copper 110 Plate
1" x 3.25" x 7"

Transformer : Avel Y236750 330VA 25+25V
Dimensons: Diameter 4.8", Height 2.1"

I rounded up the number, and I think this will make the chassis have enough room. Since my transformer's height is 2.1. My chassis width is 4", actural spacing is 4"-0.375"x2=3.25". It have more than enough space for the transformer and the PCB placing horionztally. The actural length space will be 9"-0.375"x2-4.8"(The Xformer)-1"(The Copper)-1"(the PCB)=1.45" I think this will be enough space for wiring.

Do you guys think a Dremel rotary cut will help me cut the AC Inlet hole on the 3/8" thick aluminum? IF it does help, which one should I pick from HD? $$<100

[S.C]

Originally posted by elizard
I found it that most of these stores are quite expensive, including online metals.

The shop I got my aluminum from is called speedymetals
just as an illustration of the price, one 9"x3.5" 1/8" (6061-t651) plate cost me $3.78 ..
no minimum orders, no charges for cutting

sadly, no website, but if you email them at speedymtls AT aol DOT com they'll give you a quote (btw, i did the email like that so i don't cause them griefs w/ spam)

Speedy Metal is this their logo?

[lgreen]

Hope this helps- I have found that files help a whole lot when working with metal. For my AC inlet and XLR connectors, I drilled the biggest hole I could (maybe a 1/2 inch hole) and then used a large file to get it to roughly the correct size, tweaking with smaller files. You can continuously monitor your progress and it actually doesn't take much time, although it does take much effort. For the AC inlet, download a pdf from digikey of the part and outline the dimensions on the panel, then drill a hole and file away. Obviously the thicker the metal, the tougher to file, but even with thick metal its faster than you think.

Here is an example of what I have done:



Kind of crummy, huh? Here is the view from the outside after putting on the connectors with the cover propped on.

[staff]

Anyone heard of the Dremel.
Wonderful tool for mods.

[elizard]

Originally posted by S.C




Speedy Metal is this their logo?

Yes it is.

[sam9]

S.C.,

Since the Author pannel says you are in Milpitas, I suggest you take a run over HSC at the corner or Central Expressway and Lawrence. Often there is a lot of junk out in from that you can gut for an enclosure -- they come in all sizes and shapes.

Also look in the box (it was there last week) toward the back of the shop near the heatsinks. They have (had?) a pile of rectangular extrusions that just need fron and rear pannels. The extrusion is heavy enough you might make it do doublr duty as the heatsink.

Anyway, if you are doing DIY you really should check out HSC. If nothing else, the place has a long colorful history -- they say Ted Hof and even Wozniak still drop by sometimes to look for useful junk!

[S.C]

hehe, nice to know there is a local who know my area that well. I will go there and see what I get. I had been there a couple times before. Anyway I'm in a good mood right now, cuz I'm one course away from English 1A. I think my English have improved since I come to US. HSC

P.S: Any thought on the Dremel rotary cut? Will I be able to cut through a 3/8" thick aluminum?

[sam9]

I'm sure you can cut through 3/8" Al with a Dremel but it taked time and may not be very neat. When I needed a front plate, I oredered it pre cut by www.onlinemetals.com. Then I drilled it mayself. Drilling is much easier to be neat about than cutting rectangles.