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post #11 of 68
Nice metal work. thumb.gif

Will you be powdercoating or try and keep the metal finish?
   
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post #12 of 68
Thread Starter 
Quote:
Originally Posted by sinnedone View Post

Nice metal work. thumb.gif

Will you be powdercoating or try and keep the metal finish?

Thanks!! The metal work looks ok in pictures but i am doing most everything with a jig saw and a set of hand files so its a lot of very time consuming work! 1/8th aluminum has a fantastic look and makes the whole project VERY solid VERY substantial, but it is difficult to work with.

I was thinking about a powdercoat, maybe a pearl white. I loved the look of the raw aluminium but no matter how hard i tried small scratches appear everywhere.
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post #13 of 68
Quote:
Originally Posted by coookiemunster View Post

Thanks!! The metal work looks ok in pictures but i am doing most everything with a jig saw and a set of hand files so its a lot of very time consuming work! 1/8th aluminum has a fantastic look and makes the whole project VERY solid VERY substantial, but it is difficult to work with.

I was thinking about a powdercoat, maybe a pearl white. I loved the look of the raw aluminium but no matter how hard i tried small scratches appear everywhere.

I know what you mean about trying to protect the metal finish while working with it. Maybe some sanding after its finished will give it a nice look? Powdercoating will look very nice as well. biggrin.gif
   
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post #14 of 68
Quote:
Originally Posted by coookiemunster View Post

...I loved the look of the raw aluminium but no matter how hard i tried small scratches appear everywhere.

Mayhap clear coating it will minimize scratching?
     
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post #15 of 68
Quote:
Originally Posted by Lady Fitzgerald View Post

Mayhap clear coating it will minimize scratching?

No it will actually just result in the clear getting scratched as well.

The only way to save it would be to wait after all the fabrication is done then run sandpaper of proper grit to give the desired finish. ie rougher grit for a brushed look and finer for a more finished/polished look.
   
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post #16 of 68
Quote:
Originally Posted by sinnedone View Post

Quote:
Originally Posted by Lady Fitzgerald View Post

Mayhap clear coating it will minimize scratching?

No it will actually just result in the clear getting scratched as well.

The only way to save it would be to wait after all the fabrication is done then run sandpaper of proper grit to give the desired finish. ie rougher grit for a brushed look and finer for a more finished/polished look.

I disagree somewhat. One can put tape over the aluminum to prevent, or, at least, minimize scratching during fabrication. Clear coat will protect the surface of the aluminum itself after fabrication. The clear coat will show scratching less than the aluminum itself. Furniture polish will dramatically reduce the visibility of fine scratching and also help repel dust for a while (I polish mine every week or two; it only takes a minute or two).
     
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post #17 of 68
Very nice build so far coookiemunster thumb.gif,

You have my total respect working with 1/8th aluminium, I am working on a custom 3mm acrylic case and that is bad enough 8-)
post #18 of 68
I've got what is probably a stupid question. Why did you decide on 1/8" aluminum instead of something thinner, lighter, and less expensive?

Also, how are you going to secure the panels to the frame?
     
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post #19 of 68
Thread Starter 
Quote:
Originally Posted by Lady Fitzgerald View Post

I've got what is probably a stupid question. Why did you decide on 1/8" aluminum instead of something thinner, lighter, and less expensive?

Also, how are you going to secure the panels to the frame?

Totally not a stupid question!!
So i found this shop called Laser Fab ( http://laser-fab.com/ ) and these guys are AWESOME!! They provided the 1/8 the Aluminium with all of the windows, rad fan holes and bottom arcs cut out for about half the cost that I could find anywhere else in my area. they were fast and the end product was beyond anything I could have done myself. I still had a lot of other cuts to make as I am doing a lot of experimentation as i go and have made quite a few design changes. The actual cost for the panels plus the 80/20 frame was MUCH less than the cost of a Cosmos Ultra 2.

To attach the panels to the frame I purchased these crazy strong magnets that have a step out machined in them https://www.kjmagnetics.com/proddetail.asp?prod=SDX06-OUT and I am adding a flange using L profile and square tube that will act as a support on the top and sides (and give me a place to put a dust seal) then i drill a hole in the flange big enough for the magnet to slide in but not through. (the magnet sits flush) and then attach a ferrous metal plate on the inside of the panel using construction adhesive.

I haven't posted any pics of this yet because I am still fooling around with the design and how it will integrate into the case.
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post #20 of 68
Quote:
Originally Posted by coookiemunster View Post

Quote:
Originally Posted by Lady Fitzgerald View Post

I've got what is probably a stupid question. Why did you decide on 1/8" aluminum instead of something thinner, lighter, and less expensive?

Also, how are you going to secure the panels to the frame?

Totally not a stupid question!!
So i found this shop called Laser Fab ( http://laser-fab.com/ ) and these guys are AWESOME!! They provided the 1/8 the Aluminium with all of the windows, rad fan holes and bottom arcs cut out for about half the cost that I could find anywhere else in my area. they were fast and the end product was beyond anything I could have done myself. I still had a lot of other cuts to make as I am doing a lot of experimentation as i go and have made quite a few design changes. The actual cost for the panels plus the 80/20 frame was MUCH less than the cost of a Cosmos Ultra 2.

To attach the panels to the frame I purchased these crazy strong magnets that have a step out machined in them https://www.kjmagnetics.com/proddetail.asp?prod=SDX06-OUT and I am adding a flange using L profile and square tube that will act as a support on the top and sides (and give me a place to put a dust seal) then i drill a hole in the flange big enough for the magnet to slide in but not through. (the magnet sits flush) and then attach a ferrous metal plate on the inside of the panel using construction adhesive.

I haven't posted any pics of this yet because I am still fooling around with the design and how it will integrate into the case.

Yep, it's hard to argue with a lower bottom line biggrin.gif . In my case (pardon the pun), however, weight would be a serious issue. Btw, thank you for turning me onto a manufacturer of aluminum extrusions I like. I've already located a local distributor for 80/20 even though I don't plan on building a new case for a few years (I am slowly collecting parts, though) since I want to wait until it is practical for me to switch to all SSDs in my machine.

I was thinking of fastening thin steel angles to the extrusions to form a flange for the panels to register against and using magnetic tape on the edges of the panels to secure the panel to the flange. An alternative would be to use aluminum angles to form the flange and put the magnetic tape on both the flange and the panel.
Edited by Lady Fitzgerald - 9/26/15 at 4:25am
     
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