Check it out.
And now how it happened
I started with a template for routing the 1/2" smoked acrylic
Attached the template with doublesided tape
I removed as much material as possible so as to make the routing smoother
It's a bit tedious to cut such thick acrylic with a holesaw but I used compressed air to keep the holesaw cool and eject the chips
One side gets a fancy notch for the ports on the rad and I use a smaller holesaw to remove that material
And the bandsaw to remove the rest of the waste
I use a flush trimming bit in my router table to trim the acrylic to the profile of the template
Trimming complete
I use the template to guide the acrylic drilling bit
And follow up with the 8-32 tap
Then a chamfer the edge with a different router
This is a huge mess
And one more router to put an 1/8" radius on the fan holes
This cuts down the blade noise on the fans
Test fitting fans
Then after some block sanding to take out the ripples left by the router and another pass of three through the chamfer bit the parts are ready to assemble
I used strips slightly wider than the GTX480 of the 1/2" material and fused the parts together.
Acrylic always seems to have a bow to it so I pressed it flat on my tablesaw which is the flattest table I have.
Somehow Venus manages to sleep through most of it
Edited by CyberDruid - 11/27/09 at 1:01pm
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