DIY Aluminum Case

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I searched around for a while and couldn't find anything. Does anyone know of any guides or build threads or anything that would help me with designing/building a DIY aluminum case for a power amplifier?

Also, does anyone know the approximate cost for a front panel from frontpanelexpress? Say 12"x5"x10mm thick. Or if anyone has a link to where the pricing is calculated that would be great.

Thanks.
 
raw aluminium.
 

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Here is an example, still a work in progress, but starting to come together.

Front panel is 12" x 4", and you could easily make it higher if you like that general approach. Just large enough for a 4.5~5" diameter transformer, and power supply board that fits into a 5x9" space, allowing some room for wiring. The chassis is built around the heatsinks.

I can post more info, and you can also see my post here:

http://www.diyaudio.com/forums/solid-state/231662-peeceebee-53.html#post3512021

All of the pieces are flat, no bending. any piece can be removed individually.
 

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I opened up a storebought B&K ST-140 power amplifier last weekend, to see how the chassis was made. It is a very simple affair: 2 pieces of bent sheetmetal (the bottom+sides, and the rear panel), 1 piece of unbent sheetmetal (the top), and 1 piece of thick, unbent, brushed aluminum: the front panel.

Here's a diagram of the chassis parts, plus a couple of low-res photos I grabbed from Google Images.
 

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