looking for a chassis

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I am using a Hammond RM1U1908SBK for a project, and they are pretty. They are also rather expensive, and the panels are not flat. The RMC series are not as pretty, but they are less expensive and I believe the panels are flat.
 
Thanks all. I wound up getting a RMCS9018BK1. It's not perfect but it'll hold me over until I decide what I really want or have the time to whip up a custom design for something like protocase.

Now all I have to figure out is how to get a perfectly square hole cutout for the LCD...
 
If the size were close I was going to suggest a Greenlee chassis punch. Greenlee makes a punch 2.559" wide but it is 1.378" high. I have a nibbler that I've used for rectangular holes, but in my hands the edges turn out a little rough. Another method is to drill a row of small holes along the inside of the rectangle, break the center free, and file down the sharp points.

You could always get a milling machine or maybe use a milling bit in the dremel. I don't have a milling machine but I have a new drill press, and if I were wanting to make a rectangular hole I would consider abusing the drill press with an edge milling bit. Worst that would happen is a broken bit in your face and a ruined part and damaged drill.

Perhaps the best advice is to avoid parts that require non-round holes.
 
If your prime concern is "front panel look-alike", why not use a standard rack chassis, and go with a front panel from (ta-daahhh.....) Front Panel Express. With FPE, you design it on line, and they will cut/mill/drill/anodize/stencil/label to your design. You sould be able to get a pretty good match to your DAC (depending upon your draftsman talents). FPE prices are pretty reasonable (aluminum panels....) and they provide fast, fast service.
 
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