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Old 21st April 2003, 12:32 AM   #11
EC8010 is offline EC8010  United Kingdom
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Hey, this is a family forum!
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The loudspeaker: The only commercial Hi-Fi item where a disproportionate part of the budget isn't spent on the box. And the one where it would make a difference...
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Old 21st April 2003, 01:29 AM   #12
Morse is offline Morse  United States
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Hi King 30;

>>>...Do you have a shot of the bottom?<<<

Sorry, but those are the only 2 pics we had time to snap - the bottom's a piece of .028" thick scrap aluminium I had lying about the place. I cut it with metal shears and rounded the edges, then drilled it for 8 holes - 4 of which are for the rubber feet and the other 4 of which are for phillips headed sheet metal screws.

It doesn't seem to generate much in the way of heat (there's about 4.3 watts of waste heat generated in there, but it's a big chassis....) or I would have put in a small 12V fan running at reduced RPM's off the heater windings.

Oh, some things I should have mentioned earlier -

1. If you're new to drilling sheet metal, be wary of the drill bit 'catching' and trying to screw it's way through the metal. It's easy to lose control of the work piece if that happens. Usually I clamp the work piece to the bench and put a piece of scrap wood behind it.

2. Also, be aware that you really should predrill any holes in hardwood. It's not soft pine where you can just drive a wood screw in anywhere without cracking!

3. For square holes in aluminium, if you don't have access to an end mill, you can just drill a series of small holes adjacent to each other (like a postage stamp). Then you can go to a larger bit and make the webbing between holes small enough that you can chisel it out with a cold chisel and a hammer. You do need to make the hole undersize though and do the final work with a bastard file. It takes me about an hour to put in the square hole for an IEC connector to put it into perspective.

Good luck!!

Hi EC8010;

>>>...Hey, this is a family forum!<<<

LOL!!

I felt a little bad when I saw that my post was apparently automatically censored to omit the type of punch I used though! FWIW, anyone reading this can also use a 'centre punch' though it's harder to accurately scribe lines than with a 'pr**k punch' because the angle of the tip is different.

All the best,
Morse
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Old 21st April 2003, 01:36 AM   #13
EC8010 is offline EC8010  United Kingdom
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Default The easy way

IECs are a so-and-so. But the way to do irregular holes is with an "Abrafile" blade in in a hacksaw frame. It's a coarse round file about 1/16" in diameter, and works like a saw, but cuts in any direction, an IEC socket can be cut then trimmed in 15 minutes...
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Old 21st April 2003, 01:57 AM   #14
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If you can get a jig saw table you can make square holes even faster. I build musical instruments, and one of the instruments I make is the hurdy-gurdy. It has fourty eight rectangular holes in it, each around 1/4 inch x 3/8 inch. By drilling each hole out with a smaller drill bit, I then place each holeonto the jig saw table with the blade in the hole. I can move the wood back and forth while the edge of the blade cuts the side of the hole flat. I do all fourty eight holes in less then two hours, with a little touch up work with a file after that. Total time would be about 2 1/2 hours.
Untill someone invents a sguare drill bit, this is the most efficient way I have been able to figure out how to make square/rectangular holes. I wish someone would invent one, though, to make it even easier.
Dave
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Old 21st April 2003, 06:43 AM   #15
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Wow, that's nice.


But I'm still a metal man (i.e. a Real Man ).

For drilling sheet, you can even try clamping it between two boards, though you'll have to be careful on locating the exact placement of the hole.

Tim (back from lots of filing and drilling and greasy hands working on a fresh casting)
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Old 21st April 2003, 02:47 PM   #16
Morse is offline Morse  United States
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Hi EC8010;

Thanks for the tip on the 'abrafile' blade - do you know if they're available anywhere on this side of the pond?

Hi Hurdy Gurdyman;

I always said that there's a lot that hifi afficionados can learn from the musical instrument makers, and you've proven it again! Thanks!

Hi Tim;

>>>...But I'm still a metal man...<<<

No problem there - one of these days I'd love to get time on a milling machine and have the money for a big billet of 6061 T6 so I could build a Zen SS amp into the hollows of a one piece chassis/heat sink. I have most of the parts sourced, save the PS caps and the PS trafo. $$ are the problem at the moment though, *sigh*.

For valve kit I still like the 'pseudo Victorian' look (to quote one of my friends description).

What I'd really love to do if I could just get a good stock of nixies, is to build my own CD player with a wooden chassis, nice big bat handled momentary switches as the controls, valves for the audio stage, and nixies for the display.... But as usual, $$ are a limit.

All the best,
Morse
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Old 21st April 2003, 07:04 PM   #17
EC8010 is offline EC8010  United Kingdom
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Default Abrafile

Abrafile "blades" are available from Farnell, who are worldwide, the clips to allow them to fit a standard hacksaw frame are expensive for what they are, but the final tool is excellent. I usually use it in lieu of my milling machine...
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