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Warfarin88 · 02-21-09

Hallelujah Cattle.

I got some mileage out of that little jig this morning. To compensate for the way the frames are offset into the case to allow for the side panels to slide on and off freely, I needed to add a new pair of holes to my jig:

I actually used the old pair of holes to drill a new pair of holes in a different piece of scrap so that I could use it as a jig for my jig just so that my spacing would remain consistent.

I did separately drill the initial tie in for each frame member, and then bolted it into place. I used the farther set of holes for the case chassis, and the nearer set for the internal frame piece. That way I was sure my spacing from the edge would be where I wanted it.

After I got a corner in place however, I reverted to drilling through chassis and new frame tab together. I used a bit of wood to assist the clamping process and make sure the tab didn't wander when the drill bit punched through the first layer of metal:

For the final pair of tabs on the back of the lower piece, I needed to offset another half an inch to account for the mobo tray. I also had to mangle my jig to make room for some rivets and keep the template flush to the chassis. No worries though, the jigs work was nearly finished:

10 pairs of screw holes later, I was done, and the whole thing dropped into place like it was meant to be there. Twenty 3/16" holes into two seperate planes for twenty different M4 bolts, and they all lined up perfectly.

Tolerances were tight, but careful measurements paid off, and everything lined up just as it should in the end:

So, I'm finally back to where I was a week ago lol. It probably seems like a lot of work for nothing, but the new internal frame uses only four pieces, the old one used nine. In addition, the first frame had 38 bolts holding it together, but only 12 tie in points to the primary chassis, only four of which were M4 (the rest were smaller M3's).

This new version uses 28 bolts, all M4, but it has 5 fewer pieces to hold together, and it ties into the chassis at twenty points. Needless to say, its much more solid.

Now I'm off again. I need to sort the pump / res tray for up top.

Also, I tossed out a powder coating question over in the case mod forum, if anyone has any experience there. (I want to know what I can use to fill the various unused holes in the chassis before I have it coated)

02-21-09	#188 (permalink)
Warfarin88 _______________ Join Date: Feb 2008 Posts: 843 Rep: 166 Unique Rep: 117 Trader Rating: 0	Hallelujah Cattle. I got some mileage out of that little jig this morning. To compensate for the way the frames are offset into the case to allow for the side panels to slide on and off freely, I needed to add a new pair of holes to my jig: I actually used the old pair of holes to drill a new pair of holes in a different piece of scrap so that I could use it as a jig for my jig just so that my spacing would remain consistent. I did separately drill the initial tie in for each frame member, and then bolted it into place. I used the farther set of holes for the case chassis, and the nearer set for the internal frame piece. That way I was sure my spacing from the edge would be where I wanted it. After I got a corner in place however, I reverted to drilling through chassis and new frame tab together. I used a bit of wood to assist the clamping process and make sure the tab didn't wander when the drill bit punched through the first layer of metal: For the final pair of tabs on the back of the lower piece, I needed to offset another half an inch to account for the mobo tray. I also had to mangle my jig to make room for some rivets and keep the template flush to the chassis. No worries though, the jigs work was nearly finished: 10 pairs of screw holes later, I was done, and the whole thing dropped into place like it was meant to be there. Twenty 3/16" holes into two seperate planes for twenty different M4 bolts, and they all lined up perfectly. Tolerances were tight, but careful measurements paid off, and everything lined up just as it should in the end: So, I'm finally back to where I was a week ago lol. It probably seems like a lot of work for nothing, but the new internal frame uses only four pieces, the old one used nine. In addition, the first frame had 38 bolts holding it together, but only 12 tie in points to the primary chassis, only four of which were M4 (the rest were smaller M3's). This new version uses 28 bolts, all M4, but it has 5 fewer pieces to hold together, and it ties into the chassis at twenty points. Needless to say, its much more solid. Now I'm off again. I need to sort the pump / res tray for up top. Also, I tossed out a powder coating question over in the case mod forum, if anyone has any experience there. (I want to know what I can use to fill the various unused holes in the chassis before I have it coated)