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Old 31st Jan 2009, 23:29   #21
tominated
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as you may have just discovered. acrylic is best cut using the slow setting on power tools.
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Old 1st Feb 2009, 02:51   #22
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Yeah slow and steady with acrylic. Drop the RPM down on the scroll saw and it will cut the plexi not melt it.
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Old 1st Feb 2009, 04:10   #23
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Yeah slow and steady with acrylic. Drop the RPM down on the scroll saw and it will cut the plexi not melt it.
It has 2 settings, high and low. It melted the plexi on both
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Old 1st Feb 2009, 04:15   #24
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You have a very-cool (unique) project underway..
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Old 1st Feb 2009, 05:07   #25
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Then it looks like you may have to use a Dremel or a Jigsaw for the inside cuts.
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Old 1st Feb 2009, 06:00   #26
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What kind of blades are you using? Maybe try getting some specifically made for plastic. My scroll saw (Delta) worked great on plexi. But I used the wrong blades so the cuts were ugly.
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Old 1st Feb 2009, 06:19   #27
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You have a very-cool (unique) project underway..
Thanks.

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Then it looks like you may have to use a Dremel or a Jigsaw for the inside cuts.
Yarrrgg

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What kind of blades are you using? Maybe try getting some specifically made for plastic. My scroll saw (Delta) worked great on plexi. But I used the wrong blades so the cuts were ugly.
It was probably a blade designed for wood. I didn't even think about it. There a quite a few other blades I can try; there's a whole container full next to the saw.

I was bored today so I messed around in the shop trying to come up with a decent design for the case feet. Here's what I came up with.









It was a lot of work making those 2 pieces of 1/4" aluminum perfectly round... But I think it turned out pretty well. I won't use this particular foot on the final case as it's not quite up to scratch. However I will probably use the design. Thoughts?

Last edited by legoman666; 1st Feb 2009 at 16:18.
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Old 1st Feb 2009, 06:50   #28
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Very cool foot design! To reproduce them easier you could just buy aluminum round rod the right diameter and cut 1/4" slices off.

looks great!
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Old 1st Feb 2009, 08:53   #29
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wow. i like that foot, especially the lighting effect
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Old 1st Feb 2009, 11:03   #30
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Now they are cool case feet. I may need to ste...I mean borrow that design .
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Old 1st Feb 2009, 18:49   #31
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Foot Making Process

Here's the process by which I make the feet. It's a lot of work.


First I made a template so I don't have 4 slightly different feet on my case.


I traced the outline onto a big piece of 1/4" thick aluminum.




I do the rough cuts with a band saw.


Then I drill a hole in the center so I can stick a bolt through it.


I made a little jig on the belt sander so I can easily do the rough sanding. I just stick the bolt with the rough cuts into the wood and slowly spin it to a circle.


It gets hot enough that I often have to dunk the aluminum into water. You can see the water boiling in this pic.


All done on the belt sander....


...Now onto the drill press. I moved the belts around to get around 2000 RPM. On the press I use various grits of sandpaper to get the edges nice and smooth.


Then I put the template back on and drill the remaining two holes.


And tap them.


I use a bigger drill bit to countersink the screws.


I repeat the process with the piece of plexiglass and then sandwich it between the two discs of aluminum.


All done and polished. (Or at least as smooth as I care to make it.) 1 foot took about 1.5 hours to make.


Final product.
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Old 1st Feb 2009, 19:50   #32
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Excellent work, but please mount the discs much closer to the chuck in the drill press. I know it's a 1/4" bolt, but if it goes off balance the results are deadly!

The plexi you were working with was likely extruded plexi. Yeah, it sucks... Cell cast stuff can be cut with a scroll saw. You can cut this stuff with one if you add a little water to the process. It's tricky and a little dangerous, and it slows the cutting down a lot. Just don't get the motor or switches wet.

Last edited by Cheapskate; 1st Feb 2009 at 19:57.
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Old 1st Feb 2009, 22:29   #33
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Interesting project, Ill follow your progress!
Anyway, for the sensor probe in the tubing, use a T junction, it's easy to work with!
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Old 1st Feb 2009, 23:56   #34
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Nice foot and with the red light it give a good effect
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Old 2nd Feb 2009, 01:05   #35
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Looks good!
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Old 2nd Feb 2009, 14:10   #36
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Excellent work, but please mount the discs much closer to the chuck in the drill press. I know it's a 1/4" bolt, but if it goes off balance the results are deadly!

The plexi you were working with was likely extruded plexi. Yeah, it sucks... Cell cast stuff can be cut with a scroll saw. You can cut this stuff with one if you add a little water to the process. It's tricky and a little dangerous, and it slows the cutting down a lot. Just don't get the motor or switches wet.
Good advice, I hadn't thought about it becoming unbalanced while spinning at 2000RPM. I made another foot last night and I pushed the bolt as far into the chuck as I could.

The plexi I ordered for the tank is all cast, not extruded. Hopefully should be easier to work with.

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Interesting project, Ill follow your progress!
Anyway, for the sensor probe in the tubing, use a T junction, it's easy to work with!
That's the plan!

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Nice foot and with the red light it give a good effect
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Looks good!
Thanks!
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Old 4th Feb 2009, 04:31   #37
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PS, I need a better name. Start the suggestions.
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Old 4th Feb 2009, 04:40   #38
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Wet Tech? lol
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Old 4th Feb 2009, 06:04   #39
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Wet Tech
+1
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Old 4th Feb 2009, 14:03   #40
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+1
Yes but is oil considered wet?
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