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Old 12-09-07   #31 (permalink)
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Te most difficult art will be getting the 8 mitered pieces for the last w panels done u right and smoothed out. Lots of tesious hand sanding with a jig is ahead of me tomorrow.

Then som brackets and the rest should flow.

I am pushing to have this Kooler ready to ship by Wednesday.
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Old 12-09-07   #32 (permalink)
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CD, what kind of saw blade do you use to cut that aluminum? I have no idea what you would use to cut aluminum with a saw blade.
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Old 12-09-07   #33 (permalink)
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Use a ATB (or triple chip) high tooth count (80 for 10") carbide with negative rake. Negative rake is key. I have a special blade for the table saw that I have sliced up 1/4" plate with when I built a massive 13'-9" sectional dashboard for an Azimut.

Talk about hairy I had ten pound piece back up on me hard enough to tear some skin...and messy as I use a wax type lube that I press against the blade during a cut...

For the bandsaw you want a fairly coarse bimetal like 16-18 tpi up to about 1/4" plate although carbide is preferred for thick stuff...you can cut dry if you want but the blades will burn up pretty fast.

Aluminum is really gummy and will rapidlyclog a typical metal purposed jigsaw blade. Bosch makes a special blade jsut for aluminum that I have used to trim some 1/2" plate when making a drop keel for a Catamaran. I went through about a dozen blades to cut about a 6' circumference...the aluminum just galls to the blade unless you use cutting oil.

On the Hitachi Compound Miter I have a special negative rake blade that works better than what I used for these pieces. I just need to locate it...the blade I made these cuts with is a 7 degree rake 60 tooth trim blade. It tends to leave a pretty serius burr and the cuts are far from smooth. If it were even a triple chip that would be smooother.

I already broke my 10" Hitachi chop saw when a piece got loose. The blade spun it into the piece and broke the bed of the saw and the fence! Luckily I was only bruised not bleeding...

It is important to keep the work piece secure while cutting. What likes to happen is the blade gets gummed up and grabs the piece and flings it into something...
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Old 12-10-07   #34 (permalink)
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wow CD. this looks fantastic! those hardlines look absolutely amazing on that as well! im glad i opted for those instead of some primo-flex or something similar. I cant tell you how excited i am about this! i must have looked at the pics 3 times yesterday!
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Old 12-10-07   #35 (permalink)
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God I love these things, you rock so hard Druid

I hope business is good enough for you to live off of.
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Old 12-10-07   #36 (permalink)
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Me too my friend...me too.

Glad you are pleased Antesignani. That's all I care about at the end of the work day: a happy client.

I'll have some updates soon
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Old 12-10-07   #37 (permalink)
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Oo keeping an eye on this one
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Old 12-10-07   #38 (permalink)
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CD...i just want to point out that you cheated... you said it will ALL fit inside the 12" cube... the res is externally mounted.... u fail jk Nice build, I <3 that fan!
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Old 12-10-07   #39 (permalink)
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I cheat!

Gotta do what I gotta do to make it happen man.
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The secret of success is to develop one’s intuition with devotion, logic and ingeniousness.
Current Project: CalligaCab: TV stand/bookshelf/PC-case

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Old 12-11-07   #40 (permalink)
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Speaking of which I should have the build 99% today.

It's unseasonably warm and very foggy right now...perfect working weather.

More tonight!
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The secret of success is to develop one’s intuition with devotion, logic and ingeniousness.
Current Project: CalligaCab: TV stand/bookshelf/PC-case

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