A simple DIY chassis is born

Vikash · 21st June 2006, 12:31 PM

I enjoyed making this simple chassis using just 4 aluminium panels and 2 heatsinks.

The top and bottom pannels sit in ridges cut into the heatisnks with a table saw, and then the front and back panels just bolt into the end fins.

Front and back panels are 8mm, and top/bottom 3mm. The top will be replaced with some perforated sheet eventually. All the panels will eventually be anodized.

Rear panel fixings are held with M3 nut and bolts, and panels that join to the heatsinks are held by M4 bolts tapped directly into the heatsnks so no additional brackets required.

Peter Daniel donated some nice fasteners for the feet.

Vikash · 21st June 2006, 12:34 PM

Peter, what's the preferred way to cut thick alu plate from the option of bandsaw and tablesaw. I've never used the bandsaw but considering investing in one.

Also, what's the preferred tool for deburring panel edges? Finally any recomendations on a linisher, or type of, as this is usually where my panels start going out of shape.

Those fasteners fit M5 tap perfectly btw.

traw · 21st June 2006, 12:39 PM

Looks excellent!

I too have tried to develop simplified chassis building techniques.

How did you cut the bar stock? Or is that a plate that's been cut down?

Cut on table saw, normal blade? Rip sheet metal on table saw and find that heat sinks often softer like sheet metal but use chop saw on bar stock.

Part I hate most is cutting square holes in bar stock... (iec jacks etc)

[EDIT]
I have a 12 inch bandsaw. Finally got better grade bi-metal blade for it. Was going through heatsinks and other angle pieces like butter, but then struggled on bar stock. Maybe I need a different grade that is softer.

jackinnj · 21st June 2006, 12:43 PM

nice work -- to debur the edges I use a scraper -- a flat piece of steel used in cabinetry.

i also have put a bull-nose (round over) on aluminum with an end mill.

fwiw, there is an entire cottage industry of proto-typing companies in the U.S. -- you just send them your AudoCAD, Solidworks etc. drawings and they send back a CNC'd part in a couple of days -- panelexpress has been advertising in some magazines but there are many, many companies doing this now.

reever · 21st June 2006, 02:40 PM

You can buy a hand deburring tool for the edges. McMaster-Carr, Grainger, and MSC all carry them. Very easy to use and finishes the edges nicely. Not very expensive either.

orthoefer · 22nd June 2006, 12:00 AM

Really beautiful work. Where are the heatsinks from?

toolsresearch · 22nd June 2006, 06:31 AM

Quote:

Originally posted by orthoefer
Really beautiful work. Where are the heatsinks from?

That is spectacular! And, yes, where are the heatsinks from?

johnm · 22nd June 2006, 08:04 AM

Very nice indeed!!! I'd love something like that for my Gainclone - unfortunately living in a small flat in London I don't have the luxury of being able to do this work myself :-(

Where did you get the aluminium from?

Cheers!

es44 · 22nd June 2006, 08:29 AM

Really nice work

I guess you can drive them forever at full volume without having to worry about them getting hot.

Thanks for sharing ideas.

All the best
Ebbe

elementx · 22nd June 2006, 11:58 AM

Yo should sell them, I'm sure you could make a few bucks off of it...

21st June 2006, 12:31 PM	#1
Vikash diyAudio Moderator Emeritus Join Date: May 2003 Location: UK	A simple DIY chassis is born I enjoyed making this simple chassis using just 4 aluminium panels and 2 heatsinks. The top and bottom pannels sit in ridges cut into the heatisnks with a table saw, and then the front and back panels just bolt into the end fins. Front and back panels are 8mm, and top/bottom 3mm. The top will be replaced with some perforated sheet eventually. All the panels will eventually be anodized. Rear panel fixings are held with M3 nut and bolts, and panels that join to the heatsinks are held by M4 bolts tapped directly into the heatsnks so no additional brackets required. Peter Daniel donated some nice fasteners for the feet. __________________ "The human mind is so constituted that it colours with its own previous conceptions any new notion that presents itself for acceptance." - J. Wilhelm. (But I still think mine sounds better than yours.)

21st June 2006, 12:34 PM	#2
Vikash diyAudio Moderator Emeritus Join Date: May 2003 Location: UK	Peter, what's the preferred way to cut thick alu plate from the option of bandsaw and tablesaw. I've never used the bandsaw but considering investing in one. Also, what's the preferred tool for deburring panel edges? Finally any recomendations on a linisher, or type of, as this is usually where my panels start going out of shape. Those fasteners fit M5 tap perfectly btw. __________________ "The human mind is so constituted that it colours with its own previous conceptions any new notion that presents itself for acceptance." - J. Wilhelm. (But I still think mine sounds better than yours.)

Thread Tools	Search this Thread
Show Printable Version Email this Page	Search this Thread: Advanced Search

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
Another GC is born!	mantisory	Chip Amps	10	6th July 2006 03:35 PM
One more DIY TT is born	livemusic	Analogue Source	18	20th December 2005 09:44 AM
New DAC born	mdlover	Digital Source	8	10th July 2003 09:20 AM
A simple chassis idea	Peter Daniel	Everything Else	34	5th December 2002 12:57 AM

New To Site?	Need Help?
Register to Participate Search Privacy Statement Contact Us	Frequently Asked Questions Did you forget your password? Mark Forums Read


	Please consider donating to help us continue to serve you. Ads on/off / Custom Title / More PMs / More album space / Advanced printing & mass image saving

21st June 2006, 12:39 PM	#3
traw diyAudio Member Join Date: Sep 2005	Looks excellent! I too have tried to develop simplified chassis building techniques. How did you cut the bar stock? Or is that a plate that's been cut down? Cut on table saw, normal blade? Rip sheet metal on table saw and find that heat sinks often softer like sheet metal but use chop saw on bar stock. Part I hate most is cutting square holes in bar stock... (iec jacks etc) [EDIT] I have a 12 inch bandsaw. Finally got better grade bi-metal blade for it. Was going through heatsinks and other angle pieces like butter, but then struggled on bar stock. Maybe I need a different grade that is softer.

21st June 2006, 12:43 PM	#4
jackinnj diyAudio Member Join Date: Apr 2002 Location: Llanddewi Brefi, NJ	nice work -- to debur the edges I use a scraper -- a flat piece of steel used in cabinetry. i also have put a bull-nose (round over) on aluminum with an end mill. fwiw, there is an entire cottage industry of proto-typing companies in the U.S. -- you just send them your AudoCAD, Solidworks etc. drawings and they send back a CNC'd part in a couple of days -- panelexpress has been advertising in some magazines but there are many, many companies doing this now.

21st June 2006, 02:40 PM	#5
reever diyAudio Member Join Date: Mar 2005 Location: Laurel Springs N.J. (Near Philly)	You can buy a hand deburring tool for the edges. McMaster-Carr, Grainger, and MSC all carry them. Very easy to use and finishes the edges nicely. Not very expensive either.

22nd June 2006, 12:00 AM	#6
orthoefer diyAudio Member Join Date: Apr 2006 Location: East TN	Really beautiful work. Where are the heatsinks from?

22nd June 2006, 08:04 AM	#8
johnm diyAudio Member Join Date: Sep 2003 Location: Hampshire	Very nice indeed!!! I'd love something like that for my Gainclone - unfortunately living in a small flat in London I don't have the luxury of being able to do this work myself :-( Where did you get the aluminium from? Cheers!

22nd June 2006, 08:29 AM	#9
es44 diyAudio Member Join Date: Apr 2005 Location: Fredericia, DK	Really nice work I guess you can drive them forever at full volume without having to worry about them getting hot. Thanks for sharing ideas. All the best Ebbe

22nd June 2006, 11:58 AM	#10
elementx diyAudio Member Join Date: Jul 2005 Location: cleveland, ohio	Yo should sell them, I'm sure you could make a few bucks off of it...

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)