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Thread: Bending aluminum into a case.

  1. #21
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    Quote Originally Posted by C4M
    You might want to invest $5 on a cheap thermometer (...)
    Oh, I was planning on it..

    I can get simple digital temperature displays that have a probe on the end of a wire, usually used for reading the temperature outside while you're inside.

    It should provide a fairly easy way to monitor the inside air temperature, even if I don't install it permanently...

  2. #22
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    I made up a foamboard model of some of the design changes I've made for my chassis, in this thread:

    http://www.mp3car.com/vbulletin/show...7&postcount=56


    And I drew up a layout in eMachineshop:

    The lower part is the bottom of the box.

    The center part is the tray that sits inside the box, and holds the 2.5" hard drive, and has a hole for the heatsink to pass through.

    The top part is the rear backplate.

    The part on the right is the cover, and has brackets for the slim CD/DVD, and a hole for the heatsink and fan.


    My aluminum should arrive by Friday, and I hope to start bending up this box soon.
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  3. #23
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    Well, my metal bender and hand tools arrived today, which is great...

    But the aluminum won't be here until Monday!


    Ah well... at least I can clean up my work room, and bolt the bender to the table.

  4. #24
    Constant Bitrate old_lou's Avatar
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    Quote Originally Posted by Giuliano
    Well, my metal bender and hand tools arrived today, which is great...

    But the aluminum won't be here until Monday!


    Ah well... at least I can clean up my work room, and bolt the bender to the table.
    Practise on some cardboard gotta get them bend radius measurements right
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  5. #25
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    Quote Originally Posted by old_lou
    Practise on some cardboard gotta get them bend radius measurements right
    Actually, that's a pretty good idea...

    I was originally thinking of using plastic sheet, but I think I can find some cardboard that's about 2mm thick..


    The cardboard will compress in the bends and the aluminum won't, but bending a few sheets of cardboard is certainly cheaper..

  6. #26
    Constant Bitrate old_lou's Avatar
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    Quote Originally Posted by Giuliano
    Actually, that's a pretty good idea...

    I was originally thinking of using plastic sheet, but I think I can find some cardboard that's about 2mm thick..


    The cardboard will compress in the bends and the aluminum won't, but bending a few sheets of cardboard is certainly cheaper..
    Find a piece of metal same thickness as the alloy mark 2 paralell lines say 4" apart then bend on the lines and you'le know how much your going to lose in the radius. Or you can use maths and work it out Or http://blog.sylvain.trudel.com/htm/S...Calculator.htm
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  7. #27
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    Great link, thanks.

  8. #28
    Variable Bitrate nzKAOSnz's Avatar
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    Hmmm. I just used 2.5mm Stainless. Man that stuff is hard.

  9. #29
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    I got my aluminum today.. nice and thick and sturdy.. 0.090" (~2.25mm) thickness 5053-H32 aluminum, 180mm X 330mm for the biggest piece.

    I'm using eMachineShop's program to model the bends with the sheet's size, and I'll see how I need to lay out the bend lines.

  10. #30
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    I used eMachineShop to model the bends, using a similar aluminum sheet, sized 2.5mm thick.

    The actual material is about 2.25mm thick, so the extra thickness of the model should give me some tolerance for making the bends.

    The material is 180mm x 330mm, which is a little more than I need, so the last bend will have some extra material on the end.


    When bent up, the box should be just about 180mm wide on the outside edges, and 176mm wide on the inside, and ~60mm tall from the outsides.

    I measured out where the bend lines should be, and accounted for the bend radii, so I'll start marking out my lines and I'll make the bends shortly...
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