Great page for learning chassis fabrication
 

I found this page of a gentleman making a computer case over the course of a year. His work is absolutely amazing. I have learned a tremendous amount from just looking at the pictures. The finished piece is on page 36.

Cygnus X1. - Overclockers Australia Forums

My big question is how do you keep a file clean after working on aluminum?

There's a brush that's designed for that, or just use a piece of brass to push out the big bits.

jeff

Just like a Wolverine, has to have help working a file.




(just kidding)

You can use your file on a piece of chalk before using the file. This makes it very easy to remove the small particles sticking in the grooves of the file. As mentioned elsewhere you can use a special brush for this and then it becomes even easier.

Karsten

A file brush is only so good. I can spend hours with a nail picking out the aluminum. I'm going to try the chalk. - Thanks Karsten!

Anyway, you should really check out this guy's computer case. It's some of the most
impressive work I have ever seen, done it a hacksaw, homemade brake, drill press and scroll saw. I learned a boatload about home chassis fabrication.

Cygnus X1. - Page 36 - Overclockers Australia Forums

I'm surprised he doesn't use a nibbler also. How does he glue the paper to the aluminum sheet? It's really strange to see EXACTLY the same plastic clamps that I have in photos from Australia.

I think he lays masking tape onto the aluminum and draws his pattern on it. I have seen people spray adhesive onto the back of laser prints and lay them onto the metal. I agree about the clamps. Seems to be an Aussie standard.

I've been taping graph paper to the metal. It does look like he's using some kind of tape, but most of the tapes I know of are not that good for marking. The surface of the tape is too rough and doesn't take ink very well. Maybe there's a special tape they use? I think the pros use bluing and put scratches on the metal to outline cuts and bends.

Yeah, I was at the Home Depot today and didn't find any kind of tape that would work well as something to write on.

I bought a spring powered punch and a scribe, as well as other stuff. I don't see what's wrong with just writing right on the metal, unless you make mistakes I guess...