Esquire-esque

[EsquireEsque]

Hi -

I'd be interested in how you shaped the aluminium..

A rear cavity is probably out of my range as yet.... and I'm liking the control plate right now.


as an aside - I was not aware you could epoxy wood to Aluminium - given that wood expands and aluminium doesn't.
I'm wondering if a sheet of aluminium foil could be epoxied between a body and a cap (shielding?)

[WeirdBits]

[…] I'd be interested in how you shaped the aluminium. […]

IIRC hacksaw, files, bench grinder, Dremel with a cutting wheel, and a sanding drum.

Of course, I had to make it twice as hard for myself… I bolted two layers of the aluminium together onto an old control plate as a template so I could cut both plates at once. If there’s a next time it’ll be only one plate at a time.

[EsquireEsque]

In using the old control plate as a template - is that just to guide you as to shape or could you use it as an edge - like you'd use a router...
Of course you couldn't use an actual router but if you did use it as an edge - does dremel have a tool with a bearing?

It's the rounded ends that i think would be the hardest (apart form the switch slit...)

It's worth a try I think - although one at a time one might be more my "speed"!

Then it's just a small matter of learning how to electroplate chrone onto it!

[EsquireEsque]

IIRC hacksaw, files, bench grinder, Dremel with a cutting wheel, and a sanding drum.

Of course, I had to make it twice as hard for myself… I bolted two layers of the aluminium together onto an old control plate as a template so I could cut both plates at once. If there’s a next time it’ll be only one plate at a time.

Your post above got me looking for "ways" - if it can be done it's an "interesting" problem to work out.

I have found that a laminating knife can be used to cut aluminium (it'll take a few passes against a straight edge, but it might be a bit easier).
Not sure if it'll work to "cut" the rounded edges - but it might make it a bit easier for a bench grinder.

[EsquireEsque]

Your post above got me looking for "ways" - if it can be done it's an "interesting" problem to work out.

I have found that a laminating knife can be used to cut aluminium (it'll take a few passes against a straight edge, but it might be a bit easier).
Not sure if it'll work to "cut" the rounded edges - but it might make it a bit easier for a bench grinder.

I have found a way to round the edges of a control panel....

Once it was cut to the right width (using the laminate knife mentioned above) = I tape an existing control panel to it and use it as a and use that as guide to sand (using the disc on a belt/disc sander and then finish by hand sanding). The harder control panel will not sand anywhere as easy as the aluminium - then move the control panel down to get the length I want, tape it down again and shape the other end.
The same taping allows me to easily drill the screw holes etc as well.