Guys, I need to make a corner out of aluminium. Its pretty simple shape, but cannot do it in hands, it would need to be done on mill or CNC. Of course, rounded internal corner is fine. I need two, I will drill holes in them and thread them. I need two of these: I put few in different angles to show the details. It is 4mm thick in all sides, made of 20x20mm cube. I neevr used lathe, but I guess easiest way to make it is to take 20x20mm cube and "scoop out" material from one corner. I hope that makes sense. Is there anyone who could make 2 of these for me? Is it easy to make?
i think the easiest way to make it would be takeing material that is 4 mm thick and cutting 45 degree edges on 2 sides then using a glue/screw (some kind of fastener) to put it all together if you use a glue you can use wax paper and a piece of squarish stock geto get all of the sides together
Thing is it's gonna support two walls in a case, so it would need to be done from one piece of alu. No glueing or anything like that. That is why I thought milling it from solid cube would be best.
milling uses a round bit, almost like a drill bit and a lathe spins the material around, granted it can make a square since you finally said what material it was going to be made out of i still think you should use a saw and put 2 45 degree cuts on 2 of the 4 edges then pick up some JB Weld and glue it (cold weld) together i would really like to see what kind case you are working on but i dont see how something could be THAT heavy (specifically a computer) to require those parts to be made out of 4mm thick solid alu
You gave me interesting idea, thanks I ordered today some JB Weld and some aluminium angle bit. Its almost 5mm thick and 10cm long, walls have 38mm. I'm going to cut out 2 pieces of it, for each corner. I'm going to cut our little squares of other 5mm alu sheet and weld them together. That angle will give me perfect corner 90 degree for walls - that additional 5mm square will be the bit that screws to the bottom and top panel. hopefully will do that this weekend. You can watch my project log here
The only thing problematic to machine would be the inner corner, all the other edges could be kept very sharp. In case you want it even more solid you can tap two holes per joint (hehe) and use deeper threaded screws to hold it before welding. I know you already ordered the JB Weld but in case you have a propane torch or some other capable heat source, I would suggest that you try brazing, which I find to be much superior to JB Welding.
Aluminum welding, yes, I saw it while ago, interesting solution, but I'm not brave enough to play with fire that way P.S. Tapping two holes - I like that!
Guys, it's fine, inner corner doesn't matter, it can be left "unscooped" Anyway, ebay bits dispatched, should have it with me by Friday - weekend modding here I come
