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Old 24th September 2009, 09:05 PM   #1061
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You are a true audio artist Fotios!
When one speaks the truth and has the art to back it up, how could it sound like arrogance!
Once again, beautiful work
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Old 24th September 2009, 10:19 PM   #1062
fotios is offline fotios  Greece
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Quote:
Originally Posted by MJL21193 View Post
You are a true audio artist Fotios!
When one speaks the truth and has the art to back it up, how could it sound like arrogance!
Once again, beautiful work
Thanks John for your comprehension.
Nevertheless i want to give another one proof for that i wrote for myself. I ask your forgiveness, because the pictures are off topic but i hope you will enjoy a little with these.
Except others, i like very much the hobby of plastic modelling. Take a look in pictures and you will understand better my talent in fine works.

Click the image to open in full size.

This is the model of a TigerI, for which i won a prize for its ZIMERIT. Instead stucko, i made the zimerit by melting the plastic surfaces with a modified soldering tip.

Click the image to open in full size.

This is the model of a groupC Sauber Mercedes which won in the Le Mans 24h race.

Click the image to open in full size.

This is the interesting part of work on this model. You can see the many details that i added in the engine compartment.

In all models you can see as well, the careful painting.

Fotios

Fotios
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Old 24th September 2009, 10:45 PM   #1063
fotios is offline fotios  Greece
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Some members, they ask to informed about the tools that i use. Well, see in the pictures bellow.

For heavy soldering works i use this

Click the image to open in full size.

For light soldering works i use this set

Click the image to open in full size.

For cutting works i use this

Click the image to open in full size.

For drilling works i use this

Click the image to open in full size.

I am kidding of course. I apologise for this, but i am some worried this moment because some health problems of my mam and because the heavy expensess in doctors. I am stony, and i have yet to pay bills of arround 800 euro.

Fotios
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Old 25th September 2009, 12:17 AM   #1064
tinitus is offline tinitus  Europe
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Impressive, at the age of 50

I looked at this tool I made in my youth
I thought, did I do that
Take a guess what its fore

In the old days a carpenter had to make his own tools, or he could not be a carpenter
Today ?

Anyway, my amps are not as impressive, dusty and all, because of house renovating
But they play, and they are quite good at that
btw, the heatsink sticks through the bottom, and air comes in only through the heatsink, and leaves at its top, which makes a VERY effective convection cooling
I had all the wood, so the boxes cost nothing, just a lot of work

Im not so skilled at electronics, and have to keep it simple
Very convenient that simple can sound good too
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Last edited by tinitus; 25th September 2009 at 12:28 AM.
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Old 25th September 2009, 12:40 AM   #1065
fotios is offline fotios  Greece
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Quote:
Originally Posted by syn08 View Post
Fotios,

A quick estimate shows that you punched about 3,500 holes only in the bottom panel. Assuming the same amount on the top panel (conservative) and 10 seconds per hole (conservative, not counting center punching, deburring, assuming one pass drill (unlikely for soft aluminum) etc...) it means you spent about 20 hours at the drilling press. One hole badly off and you could need to start over.

Unless you have a CNC tool, you are a true hero.
Syn08, you have got almost right the number of holes. The true number of holes is 3260! He must be crazy someone to make all these holes with a press drill! No, i haven't a CNC router. I did the holes with this milling tool:

Click the image to open in full size.

It is a set apparted from:
1) A WABECO 2404 multi-purpose and multi-place drill stand = 160 euro
2) A WABECO 24410 400 X 180mm X - Y table = 180 euro
3) A MULLER 900W motor = 90 euro
Each turn of worm it push forward the table by 4mm.
The thing it is not so simple. First of all, the workpiece must be aligned and tightened securelly on the table. The appropriate milling cutter is a whole story, according to the proccess and the material of workpiece. There are a lot of milling cutters but the most common are the slot drills (with 2 flutes usually) and the end mills (with 3-4 flutes). The alloy of cutter it is as well of big importance. For alu milling they used the TiAIN cutters. To make single holes in alu plate, a TiAIN slot drill with 2 flutes it is the most appropriate because its speed, but only up to 5-6mm holes. Above this, a 3 flute is prefferable. To make slots, you may use an end mill cutter with 4 flutes because its excellent finish on the cutting edges of slot. The same if you want to cut a square on the alu plate. From the above, you can understand that for the holes in the 3mm thick alu plate, i used a 3mm TiAIN slot drill with 2 flutes. I did first a calculation for fast proccess. Because one turn of the worm =4mm is very easy instead of 3/4 or 1+1/4 of one turn, i decided to use the 3mm slot drill. So, the distance between the edges of holes is 1mm. I made a stop flexible rod in touch with the turning lever so i can perceive when each turn is completed. So, each hole can be drilled at 4sec. A CNC router it makes the same at 3sec.
Thus, to drill the 3260 holes it takes: 3260 X 4sec = 13040sec = 217min = 3,6Hours. If we add some intervals for rest to relax ourself to make a cigarette, and to cooled the motor the milling cutter and the alu workpiece, say another 1,5 hour, then the total work can be finished in 5 hours. I must point out that there is no need to drill the holes in each cover seperatelly. We can align and tight the two pieces together, thus with once effort we have two workpieces drilled with perfect round holes. See the detailed picture.

Click the image to open in full size.

I give you another one picture of the alu chips to perceive how much perfect it is the cutting.

Click the image to open in full size.

Now, i hope you can understand that this work it is not a tragedy! For the drawing of a pcb in our PC we spend DAYS! A CNC router makes the same work in 2,7 hours and because it is programmed for some intervals for cooling, the total time it is 3,2 hours.
As for that, you call me hero, i am not hero. Heroes was persons like dr. Ernesto.
In this picture you can see 3 cutters, in left with 2 flutes, in middle with 3 flutes and in right with 4 flutes. The corner cutters are TiAIN, the middle not.

Click the image to open in full size.

Here it is a 12mm slot drill TiAIN with 4 flutes. You can observe that its cutting edge it is flat. And it is sharp like a razor!

Click the image to open in full size.

Fotios (no hero)
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Old 25th September 2009, 01:09 AM   #1066
fotios is offline fotios  Greece
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Quote:
Originally Posted by Wavebourn View Post
Agree.

Congratulations Fotios! Well designed, nice built!

How did you do lettering on a rear panel?
Hi Wave

The letters on rear panel are ...simple Letraset Transfers ! These i had in my stock. If you take a look in Letraset site-Online store you can find amazing new graphic materials! Just now i have seen those also me. There are a lot of amazing things. I will study the stuff in the next days most carefully.
As for the black sign with the white characters in the middle, it is from simple self adhesive A4 label printed in laser printer. So simple!
Keep up your courage brothers and we will be the winners in the end!

Fotios
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Old 25th September 2009, 01:12 AM   #1067
fotios is offline fotios  Greece
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Quote:
Originally Posted by Spirtos View Post


omg, Fotios plz tell me that you used a milling machine or cnc, because if you did all this with standard drilling equipment I will never try again to drill any chasis for my projects I think I need a

Excellent job man, what can I say.

Is the back label vinil sheet printed in laser printer?
Thanks ΠΑΤΡΙΔΑΑΑΑ for your kind words!
I hope the replies that i posted already can cover your question.

ΦΩΤΗΣ
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Old 25th September 2009, 01:29 AM   #1068
fotios is offline fotios  Greece
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Originally Posted by destroyer X View Post
You are really very good fotios..the man... Da man!.... honorable man!

I have observed a lot, into de details, to see some signals, clues, that was made at home...screw holes misaligned and so on..i found some..but was not easy...congratulations!!!

I was searching to find failures we normally do when working at home.... a non industrial construction, alignment, position of holes and so on...it looks something that went out from a factory!

Wonderfull job... please, inform how long time you have spent to build this wonderfull amplifier... 4 years?.... how long take the mechanical chassis work
Carolos, to be sincere the development of this project it tooks about 7 months included that i have redesign for 2nd time all pcbs. I had to resolve as well a lot of other circuitry problems (mainly in inputs due to volume control and the balanced input impedance to be matched with the main amplifier. But now, i am educated. I can finish a such amplifier (working like a German) in 10 days. But because i am Greek, and as he knows everyone in earth that Greeks are lazies, you may consider 2 months ONLY and if you are lucky!

Lucio
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Old 25th September 2009, 01:42 AM   #1069
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Quote:
Originally Posted by fotios View Post
Hi Wave

The letters on rear panel are ...simple Letraset Transfers ! These i had in my stock. If you take a look in Letraset site-Online store you can find amazing new graphic materials! Just now i have seen those also me. There are a lot of amazing things. I will study the stuff in the next days most carefully.
As for the black sign with the white characters in the middle, it is from simple self adhesive A4 label printed in laser printer. So simple!
Keep up your courage brothers and we will be the winners in the end!
It is impressive how well you aligned that letters, one by one!
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Old 25th September 2009, 07:57 AM   #1070
Spirtos is offline Spirtos  Greece
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My first thought when I saw the rear panel was that labeling is made with autotransfer letters, letraset or something, as many others DIYers I used them since 1989, but not in last years. After a more carefully look I decided that it is not possible, mostly because of their perfect alignment and look

Congratulations again Fotios
btw, did you purchuased the milling machine's parts locally or by online shopping? I was searching, long time ago for a similar system but I abandoned this plan when I saw that I could only find completed systems spending at least 600€ without cutting tools of course.
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