Case Construction Techniques

[Devil_H@ck]

With all the amplifiers everyone builds arround here, I thought it might be a good idea to have a topic like this were several ways to construct a case would be shown.

I know there's the topic about useful tools and techniques, but this one would only be about cases.

For example, I finally have all the aluminium cut for my JLH case (after +-3 months it was about time ). What would be the best way to attach the 4 panels & heatsinks to each other? The case 19" wide, so I guess it would be a good idea to fasten it at 14.5" too, but I have no idea what the best way is, the best being strong enough (the alu is 4mm thick) & as few visible screws/bolts as possible.

Here's a render of the case (with to few/wrong bolts of course, I wouldn't make this topic otherwise):

[jleaman]

Wow looks great.. Now to see it in person or a picture.

[Devil_H@ck]

Well, I'd need to know how to construct it to be able to make it .

I'm going to drill the ventilation holes (top & bottom panel) and turn the knob tomorrow, but I'll wait to drill the holes to screw everything together 'till I know exactly how to do it.

[jleaman]

what sofware is that.. id like to try it and show people what my ideas are for my aleph's : O )

[Devil_H@ck]

Solidworks, great piece of software and very easy to use! Website here: http://www.solidworks.com

Now, get on topic .

[Peter Daniel]

Do you really need top and bottom panels to go over heatsink fins? IMO, despite ventilation holes, the air circulation will be affected at least by 50% less efficiency.

[jleaman]

i agree with peter.. id remove that bit of metal if you could.. would help drematicly too


j"

[Devil_H@ck]

Well, I really like the look of it. I'll see if it works, if not, I'll cut off some metal. But it would be quite a lot of work, not only would I have to cut off the pieces of the top & bottom panel, but I'd also need to remove 4mm from the top and bottom of the front and back panel.

Anyway, first I'll see if it works this way.

For now, the main problem is how to attach the top & bottom panels to the enclosure. I could use a metal bar with 3 holes in it, 1 for a top/bottom bolt and 2 for bolts through the heatsink, but I'd like to know if there's any other good method of doing it.

[Peter Daniel]

Originally posted by Devil_H@ck
For now, the main problem is how to attach the top & bottom panels to the enclosure. I could use a metal bar with 3 holes in it, 1 for a top/bottom bolt and 2 for bolts through the heatsink, but I'd like to know if there's any other good method of doing it.

Why not attach it directly to heatsinks? If the base is at least 3/16" it shouldn't be a problem.

[Devil_H@ck]

I'm not sure what you mean with "the base". The alu is 4mm thick, the "back" of the heatsink is 4.6mm. So, you'd drill/tap a hole vertical in the back of the heatsink? Would M3 bolts/screws be sufficient to keep all this together? Because I think it will weight quite a bit: rougly 0.5 m² aluminium, 5 kgs of heatsinks, 2 160VA transformers, 13 PCBs, ... Also, wouldn't the sides of the hole be way to thin? There would be only 0.8mm left at the back of the hole.

If all that shouldn't be a problem, then how much M3 bolts would you advise to hold all this together?

Sorry for so much questions , as you notice I know nothing about all this.