Zen IV Progress Report

[kilowattski]

Gents,

I have some pictures below of the metal working process on my Zen IV build. The printed circuit cards are built and I have all the parts but the metal work is taking forever. My only excuse for this taking so long is that I had to learn how to operate a milling machine before I started to fabricate the chassis. I am a rookie with the milling machine, so I take my sweet time and check everything two or three times with the calipers before I make a cut. I have a good friend who is allowing me to use a milling machine in his shop every Saturday afternoon for a few hours to fabricate the amp. The only catch was that he can not help me because his business is very busy. He spent a couple of hours teaching me how to use the mill and I was on my own. I am very thankful he has allowed me to use his milling machine.

The toroids and rectifiers are to be mounted to the bottom plate and the capacitors will be mounted through the center plate. The PCB's will mount to the heatsinks above the the center plate isolating the signal path totally from the power supply. I have also cut some slots into the bottom and center plates to allow cool air to enter the bottom and escape through vents that I will cut into the top panel.

I have to fabricate the rear, top and front panels before the heatsinks go to the annodizer and the rest goes to the powder coater. I have a little something special planned for the front panel.

[Nelson Pass]

Oh Mama!

[Mad_K]

VERY impressive work!!!

I wish I has access to that kind of equipment...

[roddyama]

Originally posted by kilowattski
The only catch was that he can not help me because his business is very busy.

...and that you clean your mess when you're done.

The amp is shaping up to be a real killer.

[Blues]

You've got a heavyweight there! How heavy do you think will it be? It looks like it's going to be monoblocks. Nice job!

[Keld]

Very Nice work!!

Originally posted by kilowattski
[B]so I take my sweet time and check everything two or three times with the calipers before I make a cut.

Thats the only way do nice thing like yours! It is when you think its easy the mistakes starts.

Keld the Master of Mistakes

[Luke]

beautiful

[Blues]

QUOTE:{It looks like it's going to be monoblocks.}

Ooops! I thought the two pics where in one frame. Cool, well-thought chassis design. In putting together my Zv4, I'm trying to finish the chassis first too. If I did the circuit first I bet I'll be stuck in the sweet spot and will rush the chassis work.

[faustian bargin]

big and sweet.

what are you using for legs? they better not be pointed, or the weight will mash it right through whatever you set it on.

/andrew

[kilowattski]

Have a 8' piece of 6" wide 5/4 oak the I will glue up into a rectangular panel of 13" x 20". I will route an indentation in the top deep enough to fit a 12" x 19" piece of .125" aluminum plate. I will belt sand the aluminum to give it a brushed look and put some clear finish on it. This assembly will sit on the floor of my family room. I will turn some tip toes (cones) out of a 12" piece of 1" solid steel round tube. Yes, I get to learn how to use the metal lathe. Anyway, the amp will sit on the little platform I mentioned above. I am figuring that the amp will weigh about 70 lbs when done. It will be fun to see how close I am to my weight estimate when it is finished.